PC450 7e0

SEN03578-01
HYDRAULIC
EXCAVATOR
-7E0
PC400
PC400LC -7E0
-7E0
PC450
PC450LC -7E0
SERIAL NUMBERS
PC400/400LC- 60001-60089
PC400/400LC- 65001 and up
PC450/450LC- 30001-30058
PC450/450LC- 65001 and up
and up
SEN03580-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
00 Index and foreword
Index
Organization list of the shop manual............................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC400, 450-7E0
SEN03580-01
Organization list of the shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN03578-01

Index
Foreword and general information
SEN03579-01
SEN03580-01 q
SEN03581-01 q
01 Specification
Specification and technical data
SEN03582-00
SEN03583-00
10 Structure, function and maintenance standard

Engine and cooling system
Power train
Undercarriage and frame
Hydraulic system, Part 1
Work equipment
Cab and its attachments
Electrical system
SEN03584-00
SEN03585-00
SEN03586-00
SEN03587-00
SEN03588-00
SEN03589-00
SEN03590-00
SEN03591-00
SEN03592-00
SEN03593-00
20 Standard value table

Standard service value table
SEN03594-00
SEN03595-00
30 Testing and adjusting

Testing and adjusting, Part 1
SEN03596-01
SEN03597-01 q
SEN03598-00
SEN04149-00
40 Troubleshooting
Failure code table and fuse locations
Information related to troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN03599-00
SEN04150-00
SEN03600-00
SEN03601-00
SEN03602-00
SEN03603-00
SEN03604-00
SEN03605-00
PC400, 450-7E0
Troubleshooting of engine (S-mode)
SEN03580-01
SEN03606-00
50 Disassembly and assembly

General information on disassembly and assembly
Power train
Hydraulic system
Work equipment
Electrical system
SEN03607-01
SEN03608-01
SEN03609-01
SEN03610-01
SEN03611-00
SEN03612-01
SEN03613-00
SEN03614-00
SEN03615-01
90 Diagrams and drawings

Hydraulic diagrams and drawings
Electrical diagrams and drawings
SEN03616-00
SEN03618-00
SEN03617-00
PC400, 450-7E0
q
q
q
q
SEN03580-01
Table of contents

Index
SEN03580-01
Organization list of the shop manual .......................................................................................
2
Table of contents......................................................................................................................
4
SEN03581-01
Safety notice ............................................................................................................................
2
How to read the shop manual..................................................................................................
7
Explanation of terms for maintenance standard ......................................................................
9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
SEN03583-00
Specification dimension drawings............................................................................................
2
Specifications...........................................................................................................................
6
Weight table ............................................................................................................................. 12
Table of fuel, coolant and lubricants ........................................................................................ 16
SEN03585-00
Engine related parts.................................................................................................................
2
Radiator, oil cooler and aftercooler ..........................................................................................
3
Power train
SEN03586-00
Power train...............................................................................................................................
2
Final drive ................................................................................................................................
4
Sprocket...................................................................................................................................
6
Swing machinery .....................................................................................................................
8
Swing circle.............................................................................................................................. 10
SEN03587-00
Track frame and recoil spring ..................................................................................................
2
Idler..........................................................................................................................................
4
Carrier roller.............................................................................................................................
6
Track roller ...............................................................................................................................
7
Track shoe ...............................................................................................................................
8
SEN03588-00
Hydraulic equipment layout drawing........................................................................................
2
Hydraulic tank and filter ...........................................................................................................
4
Hydraulic pump........................................................................................................................
6
SEN03589-00
Control valve............................................................................................................................
2
CLSS ....................................................................................................................................... 26
Functions and operation by valve ............................................................................................ 30
Merge-divider valve ................................................................................................................. 47
Attachment circuit selector valve ............................................................................................. 72
Holding valve ........................................................................................................................... 74
PC400, 450-7E0
SEN03580-01

SEN03590-00
Valve control ............................................................................................................................
2
PPC valve................................................................................................................................
4
Solenoid valve ......................................................................................................................... 20
PPC accumulator..................................................................................................................... 22
Return oil filter ......................................................................................................................... 23
Center swivel joint ................................................................................................................... 24
Travel motor............................................................................................................................. 25
Swing motor............................................................................................................................. 37
Hydraulic cylinder .................................................................................................................... 46
Work equipment
SEN03591-00
Work equipment ......................................................................................................................
2
Dimensions of components .....................................................................................................
6
SEN03592-00
Air conditioner piping ...............................................................................................................
2
Electrical system
SEN03593-00
Engine control..........................................................................................................................
2
Electronic control system......................................................................................................... 11
Monitor system ........................................................................................................................ 36
Sensor ..................................................................................................................................... 54
KOMTRAX terminal system..................................................................................................... 57
SEN03595-00
Standard value table for engine related parts ..........................................................................
2
Standard value table for chassis related parts (Backhoe specification)...................................
3
Standard value table for chassis related parts (Loading shovel specification) ........................ 12
SEN03597-01
Tools for testing, adjusting and troubleshooting ......................................................................
3
Measuring engine speed .........................................................................................................
7
Measuring air boost pressure ..................................................................................................
8
Measuring exhaust temperature..............................................................................................
9
Measuring exhaust gas color................................................................................................... 10
Adjusting valve clearance........................................................................................................ 11
Measuring compression pressure ........................................................................................... 13
Measuring blow-by pressure ................................................................................................... 15
Measuring engine oil pressure ................................................................................................ 16
Handling fuel system parts ...................................................................................................... 18
Releasing residual pressure from fuel system......................................................................... 18
Measuring fuel pressure .......................................................................................................... 19
Handling during cylinder cut-out operation .............................................................................. 20
Handling during no injection cranking operation...................................................................... 20
Measuring fuel return rate and leakage................................................................................... 21
Bleeding air from fuel circuit .................................................................................................... 24
Checking fuel circuit for leakage.............................................................................................. 25
Checking and adjusting fan belt and alternator belt tension.................................................... 26
Checking and adjusting air conditioner compressor belt tension ............................................ 27
Measuring swing circle bearing clearance............................................................................... 28
Checking and adjusting track shoe tension ............................................................................. 29
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits............... 30
Measuring control circuit basic pressure ................................................................................. 34
Checking and adjusting pump PC control circuit oil pressure ................................................. 35
Checking and adjusting pump LS control circuit oil pressure .................................................. 38
Measuring solenoid valve output pressure .............................................................................. 43
Measuring PPC valve output pressure .................................................................................... 46
PC400, 450-7E0
SEN03580-01
Adjusting play of work equipment and swing PPC valves ....................................................... 47

Inspecting locations of hydraulic drift of work equipment ........................................................ 48
Releasing residual pressure from hydraulic circuit .................................................................. 50
Measuring oil leakage amount................................................................................................. 51
Bleeding air from various parts ................................................................................................ 54
SEN03598-00
Special functions of machine monitor ......................................................................................
2
SEN04149-00
Procedure for turning on KOMTRAX terminal .........................................................................
2
Indication by KOMTRAX terminal lamps .................................................................................
5
Handling voltage circuit of engine controller ............................................................................
8
Preparation work for troubleshooting of electrical system .......................................................
9
Procedure for testing diodes.................................................................................................... 14
Pm clinic service ...................................................................................................................... 15
Undercarriage troubleshooting report ...................................................................................... 22
40 Troubleshooting
SEN04150-00
Failure codes table ..................................................................................................................
2
Before carrying out troubleshooting when failure code is displayed........................................
6
SEN03600-00
Points to remember when troubleshooting ..............................................................................
2
Sequence of events in troubleshooting....................................................................................
3
Checks before troubleshooting ................................................................................................
4
Classification and troubleshooting steps .................................................................................
5
Information in troubleshooting table.........................................................................................
6
Connection table for connector pin numbers ........................................................................... 11
T- branch box and T- branch adapter table.............................................................................. 47
SEN03601-00
Failure code [A000N1] Eng. Hi Out of Std ...............................................................................
3
Failure code [AA10NX] Aircleaner Clogging............................................................................
4
Failure code [AB00KE] Charge Voltage Low ...........................................................................
6
Failure code [B@BAZG] Eng Oil Press. Low...........................................................................
8
Failure code [B@BAZK] Eng. Oil Level Low............................................................................ 10
Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 12
Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 14
Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 16
Failure code [CA111] ECM Critical Internal Failure.................................................................. 18
Failure code [CA115] Eng Ne and Bkup Speed Sens Error..................................................... 20
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 21
Failure code [CA123] Chg Air Press Sensor Low Error........................................................... 23
Failure code [CA131] Throttle Sensor High Error .................................................................... 24
Failure code [CA132] Throttle Sensor Low Error..................................................................... 26
Failure code [CA135] Eng Oil Press Sensor High Error .......................................................... 27
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................... 29
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 30
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 32
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 33
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 35
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 35
Failure code [CA221] Ambient Press Sens High Error ............................................................ 36
Failure code [CA222] Ambient Press Sens Low Error............................................................. 38
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 39
Failure code [CA234] Eng Overspeed ..................................................................................... 41
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 42
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 44
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 46
PC400, 450-7E0
SEN03580-01
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 47

Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 48
Failure code [CA273] PCV2 Short Error .................................................................................. 50
Failure code [CA274] PCV2 Open Error.................................................................................. 51
Failure code [CA322] Inj #1 Open/Short Error......................................................................... 52
SEN03602-00
Failure code [CA342] Calibration Code Incompatibility ...........................................................
3
Failure code [CA351] Injectors Drive Circuit Error...................................................................
4
Failure code [CA352] Sens Supply 1 Volt Low Error ...............................................................
6
Failure code [CA386] Sens Supply 1 Volt High Error ..............................................................
8
Failure code [CA441] Battery Voltage Low Error ..................................................................... 10
Failure code [CA442] Battery Voltage High Error .................................................................... 10
Failure code [CA449] Rail Press Very High Error .................................................................... 11
Failure code [CA451] Rail Press Sensor High Error................................................................ 12
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 14
Failure code [CA553] Rail Press High Error ............................................................................ 14
Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 15
Failure code [CA559] Rail Press Low Error............................................................................. 16
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 20
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 22
Failure code [CA757] All Persistent Data Lost Error ............................................................... 23
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 24
Failure code [CA1228] EGR Valve Servo Error 1 .................................................................... 26
Failure code [CA1625] EGR Valve Servo Error 2 .................................................................... 27
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 28
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 30
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 32
Failure code [CA2249] Rail Press Very Low Error................................................................... 33
Failure code [CA2271] EGR Valve Lift Sens High Error .......................................................... 34
Failure code [CA2272] EGR Valve Lift Sens Low Error........................................................... 36
Failure code [CA2351] EGR Valve Sol Current High Error...................................................... 38
Failure code [CA2352] EGR Valve Sol Current Low Error....................................................... 40
Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................. 41
Failure code [CA2556] Grid Htr Relay Volt High Error............................................................. 42
Failure code [D110KB] Battery Relay Drive S/C...................................................................... 44
Failure code [D196KA] Service Return Relay Disc. ................................................................ 46
Failure code [D196KB] Service Return Relay S/C .................................................................. 48
Failure code [DA25KP] Press. Sensor Power Abnormality ..................................................... 50
Failure code [DA80MA] Auto. Lub. Abnormal.......................................................................... 52
SEN03603-00
Failure code [DA2RMC] Pump Comm. Abnormality................................................................
4
Failure code [DA2SKQ] Model Selection Abnormality.............................................................
6
Failure code [DAFRMC] Monitor Comm. Abnormality .............................................................
8
Failure code [DHPAMA] F Pump P. Sensor Abnormality......................................................... 10
Failure code [DHPBMA] R Pump P. Sensor Abnormality ........................................................ 12
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality ....................................................... 14
Failure code [DHS4MA] Bucket Curl PPC Sen. Abnormality .................................................. 16
Failure code [DW43KA] Travel Speed Sol. Disc...................................................................... 18
Failure code [DW43KB] Travel Speed Sol. S/C....................................................................... 20
Failure code [DW45KA] Swing Brake Sol. Disc....................................................................... 22
Failure code [DW45KB] Swing Brake Sol. S/C........................................................................ 26
Failure code [DW91KA] Travel Junction Sol. Disc................................................................... 28
Failure code [DW91KB] Travel Junction Sol. S/C.................................................................... 30
PC400, 450-7E0
SEN03580-01
Failure code [DWJ0KA] Merge-divider Sol. Disc. .................................................................... 32

Failure code [DWJ0KB] Merge-Divider Sol. S/C...................................................................... 34
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ................................................................... 36
Failure code [DWK0KB] 2-stage Relief Sol. S/C ..................................................................... 38
Failure code [DXA0KA] PC-EPC Sol. Disc. ............................................................................. 40
Failure code [DXA0KB] PC-EPC Sol. S/C ............................................................................... 42
Failure code [DXE0KA] LS-EPC Sol. Disc............................................................................... 44
Failure code [DXE0KB] LS-EPC Sol. S/C................................................................................ 46
Failure code [DXE4KA] Service Current EPC Disc. ................................................................ 48
Failure code [DXE4KB] Service Current EPC S/C .................................................................. 49
Failure code [DY20KA] Wiper Working Abnormality................................................................ 50
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 52
Failure code [DY2CKB] Washer Drive S/C .............................................................................. 54
Failure code [DY2DKB] Wiper Drive (For) S/C ........................................................................ 56
Failure code [DY2EKB] Wiper Drive (Rev) S/C ....................................................................... 58
Troubleshooting of electrical system (E-mode)
SEN03604-00
Before carrying out troubleshooting of electrical system .........................................................
4
Information contained in troubleshooting table ........................................................................
6
E-1 Engine does not start ........................................................................................................
7
E-2 Auto-decelerator does not operate.................................................................................... 10
E-3 Automatic warming-up does not operate .......................................................................... 12
E-4 Preheater does not operate .............................................................................................. 14
E-5 All work equipment, swing, and travel mechanism do not move....................................... 16
E-6 Power maximizing function does not operate ................................................................... 18
E-7 Machine monitor does not display at all ............................................................................ 20
E-8 Machine monitor does not display some items ................................................................. 22
E-9 Contents of display by machine monitor are different from applicable machine ............... 22
E-10 Fuel level monitor was lighted in red while engine running............................................. 23
E-11 Engine coolant temperature gauge does not indicate normally ...................................... 24
E-12 Hydraulic oil temperature gauge does not indicate normally .......................................... 26
E-13 Fuel level gauge does not operate normally ................................................................... 27
E-14 Swing lock monitor does not indicate normally ............................................................... 28
E-15 When monitor switch is operated, monitor displays nothing ........................................... 30
E-16 Windowshield wiper does not operate ............................................................................ 32
E-17 Machine push-up function does not operate normally .................................................... 36
E-18 Monitoring function fails to display boom RAISE normally ........................................... 38
E-19 Monitoring function fails to display boom LOWER normally ......................................... 40
E-20 Monitoring function fails to display arm INnormally ...................................................... 42
E-21 Monitoring function fails to display arm OUT normally ................................................. 44
E-22 Monitoring function fails to display bucket CURLnormally............................................ 46
E-23 Monitoring function fails to display bucket DUMP normally .......................................... 48
E-24 Monitoring function fails to display swing normally ....................................................... 50
E-25 Monitoring function fails to display travel normally ....................................................... 52
E-26 Monitoring function fails to display travel differential pressure normally ....................... 54
E-27 Monitoring function fails to display service normally..................................................... 56
E-28 The KOMTRAX system does not operate normally ........................................................ 58
E-29 Air conditioner does not operate ..................................................................................... 60
E-30 Travel alarm does not sound or does not stop sounding ................................................ 62
E-31 Horn does not sound....................................................................................................... 64
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN03605-00
System chart for hydraulic and mechanical system.................................................................
4
Information contained in troubleshooting table ........................................................................
6
H-1 All work equipment lack power, or travel and swing speeds are slow ..............................
8
H-2 Engine speed sharply drops or engine stalls .................................................................... 10
H-3 No work equipment, swing or travel move ........................................................................ 11
H-4 Abnormal noise is heard from around hydraulic pump ..................................................... 11
H-5 Auto-decelerator does not work ........................................................................................ 12
H-6 Fine control mode does not function or responds slow..................................................... 12
PC400, 450-7E0
SEN03580-01
H-7 Boom moves slowly or lacks power .................................................................................. 13

H-8 Arm moves slowly or lacks power..................................................................................... 14
H-9 Bucket moves slowly or lacks power ................................................................................ 15
H-10 Work equipment does not move in its single operation .................................................. 15
H-11 Work equipment has a bit too fast hydraulic drift ............................................................ 16
H-12 Work equipment has big time lag ................................................................................... 18
H-13 Other work equipment moves when relieving single circuit ............................................ 18
H-14 Power max. switch does not operate.............................................................................. 18
H-15 Machine push-up function does not operate................................................................... 19
H-16 In compound operation of work equipment, speed of part loaded more is low............... 20
H-17 When machine swings and raises boom simultaneously, boom rising speed is low ...... 20
H-18 When machine swings and travels simultaneously, travel speed lowers largely ............ 20
H-19 Machine deviates during travel ....................................................................................... 21
H-20 Travel speed is low ......................................................................................................... 22
H-21 Machine is not steered well or steering power is low...................................................... 23
H-22 Travel speed does not change or travel speed is low or high......................................... 24
H-23 Travel system does not move (only one side) ................................................................ 25
H-24 Upper structure does not swing ...................................................................................... 26
H-25 Swing acceleration or swing speed is low ...................................................................... 28
H-26 Upper structure overruns remarkably when it stops swinging ........................................ 30
H-27 Large shock is made when upper structure stops swinging ........................................... 31
H-28 Large sound is made when upper structure stops swinging. .......................................... 31
H-29 Hydraulic drift of swing is large ....................................................................................... 32
H-30 Attachment circuit is not changed................................................................................... 33
H-31 Oil flow in attachment circuit cannot be controlled.......................................................... 33
SEN03606-00
Method of using troubleshooting chart ....................................................................................
4
S-1 Starting performance is poor .............................................................................................
8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations ........................................................................................ 15
S-5 Engine does not rotate smoothly ...................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 19
S-9 Oil becomes contaminated quickly ................................................................................... 20
S-10 Fuel consumption is excessive ....................................................................................... 21
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................. 22
S-12 Oil pressure drops........................................................................................................... 23
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 24
S-14 Coolant temperature becomes too high (overheating).................................................... 26
S-15 Abnormal noise is made ................................................................................................. 27
S-16 Vibration is excessive ..................................................................................................... 28
General information on disassembly and assembly
SEN03608-01
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Sketches of special tools ......................................................................................................... 11
SEN03609-01
Removal and installation of fuel supply pump assembly .........................................................
2
Removal and installation of fuel injector assembly ..................................................................
6
Removal and installation of engine front seal .......................................................................... 12
Removal and installation of engine rear seal........................................................................... 15
Removal and installation of cylinder head assembly ............................................................... 19
Removal and installation of radiator assembly ........................................................................ 28
PC400, 450-7E0
SEN03580-01
Removal and installation of hydraulic oil cooler assembly....................................................... 30

Removal and installation of aftercooler assembly ................................................................... 32
Removal and installation of engine and hydraulic oil pump assembly..................................... 33
Power train
SEN03610-01
Removal and installation of final drive assembly .....................................................................
2
Disassembly and assembly of final drive assembly.................................................................
3
Removal and installation of swing motor and swing machinery assembly .............................. 11
Disassembly and assembly of swing motor and swing machinery assembly.......................... 12
Removal and installation of swing circle assembly .................................................................. 19
SEN03611-00
Disassembly and assembly of carrier roller assembly.............................................................
2
Disassembly and assembly of track roller assembly ...............................................................
4
Disassembly and assembly of idler assembly .........................................................................
5
Disassembly and assembly of recoil spring assembly.............................................................
8
Removal and installation of sprocket ....................................................................................... 10
Expansion and installation of track shoe assembly ................................................................. 11
Removal and installation of revolving frame assembly ............................................................ 13
Removal and installation of counterweight assembly .............................................................. 16
Hydraulic system
SEN03612-01
Removal and installation of center swivel joint assembly ........................................................
2
Disassembly and assembly of center swivel joint assembly....................................................
4
Removal and installation of hydraulic tank assembly ..............................................................
5
Removal and installation of control valve assembly ................................................................
7
Disassembly and assembly of control valve assembly............................................................ 10
Removal and installation of hydraulic pump assembly ............................................................ 14
Removal and installation of oil seal in hydraulic pump input shaft........................................... 17
Disassembly and assembly of work equipment PPC valve assembly..................................... 18
Disassembly and assembly of travel PPC valve assembly ..................................................... 20
Disassembly and assembly of hydraulic cylinder assembly .................................................... 22
Work equipment
SEN03613-00
Removal and installation of work equipment assembly ...........................................................
2
SEN03614-00
Removal and installation of operators cab..............................................................................
2
Removal and installation of operators cab glass (stuck glass) ...............................................
5
Removal and installation of front window assembly ................................................................ 15
Electrical system
SEN03615-01
Removal and installation of air conditioner unit assembly .......................................................
2
Removal and Installation of KOMTRAX terminal assembly.....................................................
4
Removal and installation of monitor assembly ........................................................................
5
Removal and installation of pump controller............................................................................
6
SEN03618-00
Hydraulic circuit diagram .........................................................................................................
3
SEN03617-00
Electrical circuit diagram..........................................................................................................
3
Connector arrangement diagram.............................................................................................
5
10
PC400, 450-7E0
PC400, 450-7E0
SEN03580-01
11
SEN03580-01
PC400, 450(LC)-7E0 Hydraulic excavator

Form No. SEN03580-01
2008 KOMATSU
All Rights Reserved
Printed in Japan 06-08 (01)
12
SEN03581-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC400, 450-7E0
SEN03581-01
Safety notice
(Rev. 2008/02)
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w eld in g wo rk , alw ay s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
PC400, 450-7E0
2.
3.
SEN03581-01
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
11)
PC400, 450-7E0
7)
8)
9)
10)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul a r l y c a r e fu l t o c he c k t h a t t h ey ar e
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN03581-01
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
PC400, 450-7E0
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN03581-01
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
PC400, 450-7E0
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN03581-01
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
PC400, 450-7E0
How to read the shop manual

q
q
q
1.
SEN03581-01
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC400, 450-7E0
SEN03581-01
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
PC400, 450-7E0
SEN03581-01
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
q
Example:
Standard size
120
Tolerance
0.022
0.126
The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
PC400, 450-7E0
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN03581-01
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
PC400, 450-7E0
Handling of electric equipment and hydraulic component
SEN03581-01
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC400, 450-7E0
11
SEN03581-01
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
PC400, 450-7E0
3.
SEN03581-01
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q
When removing from clips

Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
PC400, 450-7E0
13
SEN03581-01
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
PC400, 450-7E0
3)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC400, 450-7E0
SEN03581-01
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN03581-01
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
PC400, 450-7E0
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
PC400, 450-7E0
SEN03581-01
17
SEN03581-01
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18
PC400, 450-7E0
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
PC400, 450-7E0
SEN03581-01
19
SEN03581-01
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engine
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
PC400, 450-7E0
3.
SEN03581-01
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3)
While pressing lock (D), pull out connector

(4) in the direction of the arrow.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC400, 450-7E0
21
SEN03581-01
4)
95, 125 170, 12V140 engine

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure in common rail: PFUEL etc.
(AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the

1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
PC400, 450-7E0
SEN03581-01
How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
PC400, 450-7E0
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN03581-01
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
PC400, 450-7E0
3.
SEN03581-01
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
PC400, 450-7E0
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN03581-01
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
PC400, 450-7E0
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN03581-01
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC400, 450-7E0
27
SEN03581-01
4)
5)
28
Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
PC400, 450-7E0
SEN03581-01
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC400, 450-7E0
29
SEN03581-01
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
PC400, 450-7E0
SEN03581-01
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
PC400, 450-7E0
31
SEN03581-01
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table corresponds to the bolts in Fig. B.

mm
6
8
10
12
32
Width across flats

mm
10
13
14
27
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
PC400, 450-7E0
2.
Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN03581-01
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
PC400, 450-7E0
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN03581-01
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Nominal No.
Thread diameter
Number of threads,
(mm)
type of thread
(Reference)
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
PC400, 450-7E0
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
SEN03581-01
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
PC400, 450-7E0
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
35
SEN03581-01
Conversion table
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.
Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
PC400, 450-7E0
SEN03581-01
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
PC400, 450-7E0
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN03581-01
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
PC400, 450-7E0
SEN03581-01
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
PC400, 450-7E0
39
SEN03581-01
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
PC400, 450-7E0
PC400, 450-7E0
SEN03581-01
41
SEN03581-01

2008 KOMATSU
All Rights Reserved
42
SEN03583-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
01 Specification

Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 6
Weight table .................................................................................................................................................. 12
Table of fuel, coolant and lubricants.............................................................................................................. 16
PC400, 450-7E0
SEN03583-00
01 Specification
Specification dimension drawings
Backhoe specification
Dimensions
Fixed gauge specification

Item
Unit
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
A Overall length
mm
11,940
11,940
12,040
12,040
B Overall height
mm
3,635
3,635
3,660
3,660
C Overall width
mm
3,340
3,440
3,340
3,340
D Track shoe width
mm
600
700
600
600
E Height of machine cab
mm
3,265
3,265
3,265
3,265
F Tail swing radius
mm
3,605
3,605
3,605
3,605
G Track overall length
mm
5,055
5,355
5,055
5,355
H Length of track on ground mm
4,020
4,350
4,020
4,350
555
550
555
550
Unit
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
A Overall length
mm
11,940
11,940
12,040
12,040
B Overall height
mm
3,635
3,635
3,660
3,660
C Overall width
mm
3,490
3590
3,490
3,490
D Track shoe width
mm
600
700
600
600
mm
3,265
3,265
3,265
3,265
F Tail swing radius
mm
3,605
3,605
3,605
3,605
mm
5,055
5,355
5,055
5,355
4,020
4,350
4,020
4,350
685
685
685
685
J Max. ground clearance
mm
J: Excluding height of grouser [37 mm]

Variable gauge specification
Item
mm
PC400, 450-7E0
01 Specification
SEN03583-00
Working ranges
Working range
Unit
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
A Max. digging reach
mm
12,025
12,025
12,005
12,005
B Max. digging depth
mm
7,820
7,820
7,790
7,790
C Max. digging height
mm
10,915
10,915
10,925
10,925
D Max. vertical wall depth
mm
6,870
6,870
6,600
6,600
E Max. dumping height
mm
7,565
7,565
7,625
7,625
F Min. dumping height
mm
mm
11,820
11,820
11,800
11,800
Max. reach at ground

level
PC400, 450-7E0
SEN03583-00
01 Specification
Loading shovel specification

Dimensions
Unit
PC400-7E0
Variable guage
PC400-7E0
Fixed guage
PC400LC-7E0
Variable guage
PC400LC-7E0
Fixed guage
A Overall length
mm
8,455
8,455
8,455
8,455
B Overall height
mm
4,400
4,400
4,400
4,400
C Overall width
mm
3,490
3,340
3,590
3,440
D Track shoe width
mm
600
600
700
700
mm
3,265
3,265
3,265
3,265
F Tail swing radius
mm
3,605
3,605
3,605
3,605
mm
5,055
5,055
5,355
5,355
4,020
4,020
4,350
4,350
685
555
685
550
Item
mm
PC400, 450-7E0
01 Specification
SEN03583-00
Working ranges
Working ranges
Unit
PC400-7E0
Variable guage
PC400-7E0
Fixed guage
PC400LC-7E0
Variable guage
PC400LC-7E0
Fixed guage
A Max. digging reach
mm
8,660
8,660
8,660
8,660
Maximum reach at
ground level
mm
8,375
8,375
8,375
8,375
C Max. digging height
mm
10,190
10,190
10,190
10,190
D Max. digging depth
mm
3,045
3,045
3,045
3,045
mm
4,850
4,850
4,850
4,850
mm
4,535
4,535
4,535
4,535
Working range
Min. reach at ground

level
F Min. swing radius
PC400, 450-7E0
SEN03583-00
01 Specification
Specifications
PC400-7E0, PC400LC-7E0
PC400-7E0
Machine model
Fixed gauge
spec.
Variable
gauge spec.
Performance
Working ranges
Serial number
Variable
gauge spec.
60001 and up
m3
1.9
1.9
Weight of machine
kg
41,200
42,200
mm
mm
mm
mm
mm
mm
7,820
6,870
12,025
11,820
10,915
7,565
7,820
6,870
12,025
11,820
10,915
7,565
kN {kg}
kN {kg}
rpm
deg.
km/h
deg.
256.0 {26,100}
(274.6 {28,000})
9.1
20
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
256.0 {26,100}
(274.6 {28,000})
9.1
20
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
Max. digging depth

Max. vertical wall depth
Max. digging reach
Max. reach at ground level
Max. digging height
Max. dumping height
Ground pressure
Dimensions
Fixed gauge
spec.
Bucket capacity
Max. digging force

(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
Overall length
Overall width
(Track gauge when retracted)
Overall width of track
(Track gauge when retracted)
Overall height
Overall height to top of machine
Ground clearance of upper structure
Min. ground clearance

Tail swing radius
Min. swing radius of work equipment
Height of work equipment

at min. swing radius
Length of track on ground
Track gauge
Height of machine cab
Width of standard shoe
PC400LC-7E0
kPa {kg/cm2}
77.7{0.79}
79.9 {0.82}
73.9 {0.75}
65.3 {0.67}
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
11,940
3,340
3,490
3,635
3,265
1,320
685
3,645
4,735
9,210
11,940
3,490
3,090
3,490
2,990
3,635
3,265
1,320
685
3,645
4,735
9,210
11,940
3,440
3,590
3,635
3,265
1,320
685
3,645
4,735
9,210
11,940
3,590
3,590
3,590
3,090
3,635
3,265
1,320
685
3,645
4,735
9,210
mm
mm
mm
mm
4,020
2,740
2,920
600
4,020
2,890
2,920
600
4,350
2,740
2,920
700
4,350
2,890
2,920
700
PC400, 450-7E0
01 Specification
SEN03583-00
Machine model
PC400-7E0
Serial number
60001 and up
Model
Type
mm
l {cc}
SAA6D125E-5
4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
6 125 150
11.045 {11,045}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
257/1,900 {345/1,900}
1,383/1,400 {141/1,400}
1,930
1,000
203 {147}
Engine
Performance
No. of cylinders bore stroke

Piston displacement
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption
Starting motor
Alternator
Battery
24V, 7.5 kW
24V, 35A
12V, 110 Ah 2
Aluminum wave type, 4 rows
Carrier roller
2 on each side
Track roller
7 on each side
Control valve Hydraulic pump

Hydraulic motor
Travel motor
HPV160+160 (190), variable displacement, piston type 2

l /min
345 2
MPa {kg/cm2}
37.8 {380}
Delivery
Set pressure
8 on each side
Assembly-type triple grouser, Assembly-type triple grouser,

46 on each side
49 on each side
Track shoe
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type
Type No.
PC400LC-7E0
Type No.
6-spool type + 1-spool type 1
Control method
Hydraulic
KMV200ADT-2, Variable displacement, piston type
(with brake valve, parking brake): 2
KMF230ABE-5, Fixed displacement piston type
(with safety valve, holding brake, reverse rotation preventive
valve): 1
Swing motor
Type
Boom (*1)
Arm (*1), (*2)
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
Inside diameter of cylinder
mm
160
185
160
Diameter of piston rod
mm
110
120
110
Stroke
mm
1,570
1,820
1,270
Max. distance between pins
mm
3,830
4,325
3,140
Min. distance between pins
mm
2,260
2,505
1,870
Hydraulic tank
Hydraulic filter
Hydraulic cooler
Closed box type

Tank return side
CF40-1 (Air cooled)
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
PC400, 450-7E0
SEN03583-00
01 Specification
PC450-7E0, PC450LC-7E0
PC450-7E0
Machine model
Fixed gauge
spec.
Variable gauge
spec.
Working ranges
Performance
Serial Number
m3
Operating weight
kg
Max. digging force

Swing speed
Travel speed
Gradeability
Dimensions
Ground pressure
Overall length
Overall width
Overall width when retracted
Overall width of track
Overall width of track when
retracted
Overall height
Overall height to top of machine
Ground clearance of upper structure

Tail swing radius

Track gauge
Fixed gauge
spec.
Variable gauge
spec.
30001 and up
Bucket capacity
Max. digging depth

Max. vertical wall depth
Max. digging reach
Max. digging height
Max. dumping height
PC450LC-7E0
1.9
1.9
42,700
44,000
43,700
44,600
mm
mm
mm
mm
mm
mm
7,790
6,600
12,005
11,800
10,925
7,625
7,790
6,600
12,005
11,800
10,925
7,625
kN {kg}
258.9 {26,400}
(275.5 {28,300})
9.1
17
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
258.9 {26,400}
(275.5 {28,300})
9.1
17
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
rpm
deg.
km/h
deg.
kPa {kg/cm2}
80.5 {0.82}
82.9 {0.85}
76.5 {0.78}
78.1 {0.80}
mm
mm
mm
mm
mm
12,040
3,340
3,340
12,040
3,490
3,090
3,490
2,990
12,040
3,340
3,340
12,040
3,490
3,140
3,490
2,990
mm
mm
mm
mm
mm
mm
mm
3,660
3,265
1,320
555
3,605
4,805
9,230
3,660
3,265
1,320
685
3,605
4,805
9,230
3,660
3,265
1,320
550
3,605
4,805
9,230
3,660
3,265
1,320
685
3,605
4,805
9,230
mm
mm
mm
mm
4,020
2,740
2,920
600
4,020
2,890
2,920
600
4,350
2,740
2,920
600
4,350
2,890
2,920
600
PC400, 450-7E0
01 Specification
SEN03583-00
Machine model
PC450-7E0
PC450LC-7E0
Serial number
30001 and up
Model
Type
mm
l {cc}
SAA6D125E-5
6 125 150
11.045 {11,045}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
257/1,900 {345/1,900}
1,383/1,400 {141/1,400}
1,930
1,000
203 {147}
Performance
Engine

Piston displacement
Flywheel horsepower
Max. torque
Starting motor
Alternator
Battery
24V, 7.5 kW
24 V, 35 A
12V, 110 Ah 2
2 on each side
Track roller
7 on each side
Hydraulic motor Control valve Hydraulic pump
Type No.
HPV160+160 (190), ariable displacement, piston type 2

l /min
345 2
MPa {kg/cm2}
37.8 {380}
Delivery
Set pressure
8 on each side

46 on each side
49 on each side
Track shoe
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type

Carrier roller
Type No.
Control method
Hydraulic
Travel motor
Swing motor

valve): 1
Type
Boom (*1)
Arm (*1),(*2)
Bucket
Double-acting
piston
Double-acting
piston
Double-acting
piston
mm
160
185
160
Outside diameter of piston rod
mm
110
130
110
Stroke
mm
1,570
1,985
1,270
mm
3,830
4,740
3,140
mm
2,260
2,755
1,870
Hydraulic tank
Hydraulic filter
Hydraulic cooler
Closed box type

Tank return side
CF40-1 (Air cooled)
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
PC400, 450-7E0
SEN03583-00
01 Specification

PC400, 400LC-7E0
PC400-7E0
Machine model
Fixed gauge
spec.
Working ranges
Performance
Serial Number
Dimensions
Fixed gauge
spec.
Variable gauge
spec.
60001 and up
60001 and up
Bucket capacity
m3
2.6
2.6
Operating weight
kg
43,100
44,300
mm
mm
mm
mm
mm
3,045
8,660
8,375
10,190
7,190
3,045
8,660
8,375
10,190
7,190
kN {kg}
285.2 {29,100}
285.2 {29,100}
rpm
deg.
km/h
deg.
9.1
20.0
Lo: 3.0, Hi: 5.5
35
9.1
20.0
Lo: 3.0, Hi: 5.5
35
kPa {kg/cm2}
80.5 {0.82}
[600 mm]
66.7 {0.68}
[700 mm]
Max. digging depth

Max. digging reach
Max. digging height
Max. dumping height
Max. digging force

Swing speed
Travel speed
Gradeability
Ground pressure
[standard triple grouser shoe width]
Overall length
Overall width
(when track gauge retracted)
Overall width
(when track gauge retracted)
Overall height
Overall height to top of cab
Ground clearance of counterweight

Tail swing radius

Track gauge
10
Variable gauge
spec.
PC400LC-7E0
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
8,455
3,340
3,340
3,355
3,265
1,320
555
3,645
4,850
6,370
8,455
3,490
3,090
3,490
2,990
3,355
3,265
1,320
685
3,645
4,850
6,370
8,455
3,440
3,440
3,355
3,265
1,320
550
3,645
4,850
6,370
8,455
3,590
3,140
3,590
3,090
3,355
3,265
1,320
685
3,645
4,850
6,370
mm
mm
mm
mm
4,020
2,740
2,920
600
4,020
2,890
2,920
600
4,350
2,740
2,920
700
4,350
2,890
2,920
700
PC400, 450-7E0
01 Specification
SEN03583-00
Machine model
PC400-7E0
PC400LC-7E0
Serial number
60001 and up
60001 and up
Model
Type
Performance
Engine

Piston displacement
Flywheel horsepower
Max. torque
mm
l {cc}
SAA6D125E-5
6 125 150
11.045 {11,045}
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
257/1,900 {345/1,900}
1,383/1,400 {141/1,400}
1,930
1,000
203 {147}
Starting motor
Alternator
Battery
24V, 7.5 kW
24 V, 35 A
12V, 110 Ah 2
2 on each side
Track roller
7 on each side
Hydraulic motor Control valve Hydraulic pump
Type No.
Delivery
Set pressure
8 on each side

46 on each side
49 on each side
Track shoe
HPV190+190, Variable displacement, piston type 2

l /min
345 2
MPa {kg/cm2}
34.8 {355}
Type No.
Control method
Hydraulic
Travel motor
Swing motor

valve): 1
Boom
Hydraulic cylinder
Hydraulic system
Undercarriage
Radiator core type

Carrier roller
Arm
Bucket
Bottom dump
Double-acting Double-acting Double-acting Double-acting

piston
piston
piston
piston
Type
mm
160
185
135
130
Outside diameter of piston rod
mm
110
120
95
90
Stroke
mm
1,338
1,375
1,287
284
mm
3,837
3,615
3,322
1,091
mm
2,499
2,240
2,035
807
Hydraulic tank
Hydraulic filter
Hydraulic cooler
PC400, 450-7E0
Closed box type

Tank return side
CF40-1 (Air cooled)
11
SEN03583-00
01 Specification
Weight table
PC400-7E0, PC400LC-7E0
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model
PC400-7E0
Serial number
PC400LC-7E0
60001 and up
Engine assembly
Engine
Damper
Hydraulic pump
1,660
1,314
14.7
210
1,660
1,314
14.7
210
Radiator, oil cooler assembly
213
213
Hydraulic tank, filter assembly (excluding

hydraulic oil)
198
198
Fuel tank (excluding fuel)
251
251
3,297
3,297
Operator's cab
279
279
Operator's seat
35
35
Counterweight
9,220
9,220
Swing machinery (including swing motor)
526
526
Control valve (with service valve)
257
257
Swing motor
105
105
Travel motor
208 2
208 2
40
40
Revolving frame
Center swivel joint

Fixed gauge
specification
Variable gauge
specification
Fixed gauge
specification
Variable gauge
specification
Track frame assembly
10,173
11,367
10,965
11,934
Track frame
5,506
6,766
6,077
7,096
Center frame
3,229
3,229
Crawler frame
1,754 2
1,921 2
Swing circle
605
605
Idler
230 2
230 2
Idler cushion
338 2
338 2
Carrier roller
32 4
32 4
Track roller
72 14
72 16
Final drive (including travel motor)
722 2
722 2
12
PC400, 450-7E0
01 Specification
SEN03583-00
Unit: kg
Machine model
PC400-7E0
Serial number
PC400LC-7E0
60001 and up
Track shoe assembly

Standard triple grouser shoe (600 mm)
4,470
4,760
4,890
5,210
Wide triple grouser shoe (800 mm)
5,320
5,670
6,130
Boom assembly
3,290
3,290
Arm assembly
1,374
1,374
Bucket assembly
1,366
1,366
355 2
355 2
Arm cylinder assembly
510
510
Bucket cylinder assembly
297
297
Link assembly
258
258
92 + 20 2 + 73 + 27 + 54
92 + 20 2 + 73 + 27 + 54
Arm pin
17 + 23
17 + 23
Bucket pin
38 2
38 2
Link pin
34 2
34 2
Boom cylinder assembly
Boom pin
PC400, 450-7E0
13
SEN03583-00
01 Specification
PC450-7E0, PC450LC-7E0
Unit: kg
Machine model
PC450-7E0
Serial number
PC450LC-7E0
30001 and up
Engine assembly
Engine
Damper
Hydraulic pump
1,660
1,314
14.7
210
1,660
1,314
14.7
210
Radiator oil cooler assembly
213
213
Hydraulic tank, filter assembly

(excluding hydraulic oil)
198
198
Fuel tank (excluding fuel)
251
251
3,402
3,402
Operators cab
279
279
Operators seat
35
35
Counterweight
9,220
9,220
Swing machinery
526
526
Control valve
257
257
Swing motor
105
105
Travel motor
208 2
208 2
40
40
Revolving frame
Center swivel joint

Fixed gauge
specification
Variable gauge
specification
Fixed gauge
specification
Variable gauge
specification
Track frame assembly
10,462
11,697
11,269
12,244
Track frame
5,506
6,766
6,077
7,096
Center frame
3,229
3,729
Crawler frame
1,754 2
1,921 2
Swing circle
605
605
Idler
230 2
230 2
Idler cushion
338 2
338 2
Carrier roller
32 4
32 4
Track roller
81 6, 72 8
81 8, 72 8
722 2
722 2
Final drive (including travel motor)
14
PC400, 450-7E0
01 Specification
SEN03583-00
Unit: kg
Machine model
PC450-7E0
Serial number
PC450LC-7E0
30001 and up
Track shoe assembly

4,470
4,890
4,760
5,210
Boom assembly
3,380
3,380
Arm assembly
1,622
1,622
Bucket assembly
1,941
1,941
355 2
355 2
Arm cylinder assembly
580
580
Bucket cylinder assembly
297
297
Link assembly
258
258
92 + 20 2 + 73 + 27 + 54
92 + 20 2 + 73 + 27 + 54
Arm pin
17 + 23
17 + 23
Bucket pin
38 2
38 2
Link pin
34 2
34 2
Boom cylinder assembly
Boom pin
PC400, 450-7E0
15
SEN03583-00
01 Specification
Table of fuel, coolant and lubricants

a
16
For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
PC400, 450-7E0
01 Specification
SEN03583-00
Unit: l
Reservoir
PC400/400LC-7E0, PC450/450LC-7E0
Specified (l)
Refill (l)
42
38
20.0
20.0
12
12
Damper case
1.07
1.07
Hydraulic system
472
248
Fuel tank
650
Cooling system
36
Engine oil pan

Swing machinery case
Final drive case
For the HO46-HM, use the oil recommended by Komatsu.
PC400, 450-7E0
17
SEN03583-00

2008 KOMATSU
All Rights Reserved
18
SEN03585-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
10 Structure, function and

maintenance standard

Engine related parts ........................................................................................................................................ 2
Radiator, oil cooler and aftercooler ................................................................................................................. 3
PC400, 450-7E0
SEN03585-00
Engine related parts
1. Damper assembly
2. Drive plate
3. Torsion spring
4. Stopper pin
5. Friction plate
6. Muffler
7. Rear engine mount
8. Front engine mount
Outline
A wet type damper assembly is used.
Oil capacity: 1.07 l
PC400, 450-7E0
SEN03585-00
Radiator, oil cooler and aftercooler
1.
2.
3.
4.
5.
Oil cooler
Radiator
Radiator cap
Radiator inlet hose
Reservoir tank
6.
7.
8.
9.
10.
Net
Shroud
Radiator outlet hose
Aftercooler
Condenser
Specifications
Radiator: Aluminum wave type, 4 rows
Oil cooler: CF40-1
PC400, 450-7E0
SEN03585-00

2008KOMATSU
All Rights Reserved
SEN03586-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Power train
Power train...................................................................................................................................................... 2
Final drive ....................................................................................................................................................... 4
Sprocket .......................................................................................................................................................... 6
Swing machinery............................................................................................................................................. 8
Swing circle................................................................................................................................................... 10
PC400, 450-7E0
SEN03586-00
Power train
1. Idler
2. Center swivel joint
3. Control valve
4. Final drive
5. Travel motor (KMV200ADT-2)
6. Engine (SAA6D125E-5)
7. Hydraulic pump (HPV190+190)
8. Travel speed solenoid valve
9. Swing brake solenoid valve
10. Swing machinery
11. Swing motor (KMF230ABE-5)
12. Swing circle
PC400, 450-7E0
PC400, 450-7E0
SEN03586-00
SEN03586-00
Final drive
1.
2.
3.
4.
5.
6.
7.
Level plug
Drain plug
No. 1 planetary gear (No. of teeth: 43)
No. 1 sun gear (No. of teeth: 10)
No. 2 sun gear (No. of teeth: 18)
No. 1 planetary carrier
8.
9.
10.
11.
12.
13.
Cover
Ring gear (No. of teeth: 98)
Sprocket
Floating seal
Travel motor
No. 2 planetary gear (No. of teeth: 38)
Specifications
Reduction ratio:
10 + 98 18 + 98 = 68.600
10
18
PC400, 450-7E0
SEN03586-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
14
Backlash between No. 1 sun gear

and No. 1 planetary gear
0.15 0.54
1.10
15
Backlash between No. 1 planetary

gear and ring gear
0.18 0.66
1.30
16

carrier and motor
0.06 0.24
17

0.15 0.51
1.00
18

gear and ring gear
0.17 0.60
1.20
19

carrier and No. 2 sun gear
0.15 0.54
20
Amount of wear on sprocket tooth
21
Width of sprocket tooth
PC400, 450-7E0
Replace
Repair limit: 6
Standard size
Repair limit
90
87
Rebuild or replace
SEN03586-00
Sprocket
Unit: mm
No.
Check Item
Wear of tooth tip
Thickness of tooth root
Width of tooth
Wear of tooth shape
Criteria
Standard size
Remedy
Repair limit
355
343
20.8
14.8
90
87
Build-up welding
for rebuilding or
replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth

shape)
PC400, 450-7E0
SEN03586-00
Full-size drawing of sprocket tooth shape
The above drawing is reduced to 61%. Enlarge it to 164% to return it to the full scale and make a copy
on an OHP sheet.
PC400, 450-7E0
SEN03586-00
Swing machinery
1.
2.
3.
4.
5.
6.
7.
Swing pinion (No. of teeth: 13)

Cover
Case
No. 2 planetary gear
No. 2 sun gear
Ring gear
No. 1 sun gear
8.
9.
10.
11.
12.
13.
Swing motor
Oil level gauge
No. 1 planetary gear
Drain plug
PC400, 450-7E0
SEN03586-00
1
Specifications
Reduction ratio:
19 + 68 16 + 68 = 24.039
19
16
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
14
Backlash between swing motor

shaft and No. 1 sun gear
0.18 0.28
15

0.15 0.51
1.00
16

gear and ring gear
0.17 0.60
1.10
17

carrier and No. 2 sun gear
0.40 0.75
1.20
18

0.16 0.55
1.00
19

gear and ring gear
0.17 0.60
1.10
20
Backlash between coupling and

swing pinion
0.08 0.25
21
Backlash between swing pinion and

swing circle
0.00 1.21
2.00
22
Clearance between plate and coupling
0.57 1.09
Standard size
Repair limit
23
Wear of swing pinion surface contacting with oil seal
PC400, 450-7E0
150 0
0.100
Replace
Apply hard
chrome plating,
recondition, or
replace
SEN03586-00
Swing circle
1.
2.
3.
Swing circle inner race (No. of teeth: 84)

Ball
Swing circle outer race
a.
b.
Inner race soft zone "S" position

Outer race soft zone "S" position
Specifications
Reduction ratio: 84/13 = 6.462
Amount of grease: 33 l (G2-LI)
Unit: mm
No.
10
Check Item
Axial clearance of bearing
(when mounted on chassis)
Criteria
Remedy
Standard clearance
Repair limit
0.5 1.6
3.2
Replace
PC400, 450-7E0
PC400, 450-7E0
SEN03586-00
11
SEN03586-00

2008 KOMATSU
All Rights Reserved
12
SEN03587-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0


Track frame and recoil spring.......................................................................................................................... 2
Idler ................................................................................................................................................................. 4
Carrier roller .................................................................................................................................................... 6
Track roller ...................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC400, 450-7E0
SEN03587-00
Track frame and recoil spring

a
The following drawing indicates PC400-7E0 and PC450-7E0.
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Front guard
The dimensions and the number of track rollers depend on the model, but the basic structure is not different.
Number of track rollers
Model
Q'ty (one side)
PC400, 450-7E0
PC400LC-7E0,
PC450LC-7E0
PC400, 450-7E0
SEN03587-00
Standard shoe
Models
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Shoe width
600 mm
700 mm
600 mm
600 mm
Link pitch
228 mm
228 mm
228 mm
228 mm
46 (Pieces)
49 (Pieces)
46 (Pieces)
49 (Pieces)
Item
No. of shoes (one side)
Unit: mm
No.
10
Check Item
Vertical width of idler

guide
Horizontal width of idler

guide
Criteria
Remedy
Standard size
Tolerance
Rapair limit
Track
frame
148
+3
1
Idler
support
145
0.5
Track
frame
302
+4
1
Idler
support
297
Standard size
11
Recoil spring
Free length
O.D.
845.3 262
PC400, 450-7E0
Rebuild or replace
Rapair limit
Installation
length
Installation
load
Free length
Installation
load
690
239 kN
{24,375 kg}
Replace
SEN03587-00
Idler
PC400, 450-7E0
SEN03587-00
Unit: mm
No.
Check Item
Criteria
Remedy
Standard size
Rapair limit
704
Outside diameter of tread
660
648
Depth of tread
22
28
Thickness of tread
21
15
Total width
202
Width of tread
48.5
54.5
Clearance between bushing and

support
(Sum of clearance at both sides)
0.46 0.86
Clearance between shaft and

bushing
Outside diameter of protrusion
Interference between idler and

bushing
Standard size
95
Standard size
102.6
PC400, 450-7E0
Tolerance
Shaft
Hole
0.120
0.207
+0.360
+0.220
Tolerance
Shaft
Hole
0.062
0.027
+0.037
+0.087
Rebuild or replace
Standard clearance
0.340 0.567
Replace bushing
Standard
interference
0.064 0.149
SEN03587-00
Carrier roller
Unit: mm
No.
Check Item
Criteria
Standard size
Remedy
Rapair limit
Outside diameter of flange
179
152
138
Width of tread
50.3
Thickness of tread
32
25
Width of flange
19
Clearance between shaft and bushing
Interference between roller and

bushing
Axial clearance of roller
Standard
size
54
Standard
size
61
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.250
0.280
+0.074
+0.040
0.250
0.354
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
+0.117
+0.087
+0.030
+0.040
0.057
0.117
Standard clearance
Clearance limit
0.5 0.7
Replace
PC400, 450-7E0
Track roller
SEN03587-00
Unit: mm
No.
Check Item
Criteria
Remedy
Standard size
Rapair limit
240
Outside diameter of inner flange

(Double flange)
237
200
168
Thickness of tread
56.2
48
Overal width
278
Width of tread
Width of outer
flange
Width of inner frange

(Double frame)
Axial play
Outside diameter of outer flange
10
11
Single flange
54.6
Double flange
51.6
Single flange
32.6
Double flange
32.6
23.0
0.4 1.0
Clearance between shaft and

bushing
Interference between roller and

bushing
PC400, 450-7E0
Standard
size
80
Standard
size
87.6
Build-up welding
for rebuilding or
replace
Tolerance
Shaft
Hole
0.250
0.350
+0.174
+0.029
Tolerance
Shaft
Hole
+0.108
+0.008
0.006
0.036
Standard
clearance
Clearance
limit
0.279 0.524
1.5
Standard
interference
Interference
limit
0.014 0.144
Replace bushing
SEN03587-00
Track shoe
P portion shows the link of bushing press fitting end.

Unit: mm
No.
Check Item
Link pitch
Outside diameter of bushing
Thickness of bushing metal
Link height
Thickness of link metal (bushing

press-fitting portion)
Criteria
Standard size
Remedy
Repair limit
228.9
231.9
Standard size
Reverse
71.5
66.5
11.9
6.9
Standard size
Repair limit
129
119
34.5
24.5
Reverse or replace
Adjust or replace
Repair or replace
PC400, 450-7E0
SEN03587-00
Unit: mm
No.
6
7
8
Check Item
Shoe bolt pitch
18
144
Link
Inside
width
106
Overall
width
51.6
Tread
width
44.8
Protrusion of pin
4.4
Protrusion of regular bushing
5.25
Overall length of pin
252
Overall length of bushing
Press-fitting force
Adjust or replace
Bushing
118 304 kN {12 31 ton}
Regular
pin
176 451 kN {18 46 ton}
Master
pin
137 284 kN {14 29 ton}
a. Regular link
Shoe bolt
b. Master
link
21
Repair or replace
164.5
Thickness of spacer
19
(*)
20
Replace
76.2
11
12
13
14
15
16
17
Remedy
184
9
10
Criteria
Interference between bushing and

link
22
Interference between regular pin

and link
23
Clearance between regular pin and

bushing
24
(*)
Interference between master pin

and bushing
25
(*)
Clearance between master pin and

bushing
Tightening torque
(Nm {kgm})
Triple grouser shoe
Tightening torque
(Nm {kgm})
Retightening angle (deg.)
39339
{404}
12010
Retightening angle (deg.)
Standard size
Retighten
Lower limit torque

(Nm {kgm})
Tolerance
Standard
interference
Shaft
Hole
71
+0.494
+0.454
+0.074
+0.074
0.380 0.494
47
+0.235
+0.085
0.218
0.280
0.303 0.515
Standard size
47
Standard size
47
Standard size
47
Tolerance
Shaft
Hole
+0.235
+0.085
+0.915
+0.415
Tolerance
Shaft
Hole
+0.03
+0.03
0.218
0.280
Tolerance
Shaft
Hole
0.2
0.4
+0.915
+0.415
Standard clearance
0.180 0.830
Adjust or replace
Standard interference
0.218 0.310
Standard clearance
0.615 1.315
* Dry type track link
PC400, 450-7E0
SEN03587-00
Triple grouser shoe
Unit: mm
No.
Check Item
Height
2
3
4
5
6
7
Thickness
Thickness
10
Criteria
Standard size
Remedy
Repair limit
37
22
13
33
Length of base
Build-up welding
for rebuilding or
replace
27
25.5
Length at tip
17.5
23.5
Standard size
Repair limit
50
35
PC400, 450-7E0
PC400, 450-7E0
SEN03587-00
11
SEN03587-00

2008 KOMATSU
All Rights Reserved
12
SEN03588-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0


Hydraulic equipment layout drawing ............................................................................................................... 2
Hydraulic tank and filter .................................................................................................................................. 4
Hydraulic pump ............................................................................................................................................... 6
PC400, 450-7E0
SEN03588-00
Hydraulic equipment layout drawing
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Work equipment lock lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Hydraulic drift prevention valve
19. Accumulator
20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Travel junction solenoid
20C. Pump merge-divider solenoid
20D. Travel speed solenoid
20E. Swing brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid
PC400, 450-7E0
SEN03588-00
PC400, 450-7E0
SEN03588-00
Hydraulic tank and filter
1.
2.
3.
4.
5.
6.
7.
8.
Oil filler cap

Breather
Hydraulic tank
Sight gauge
Strainer
Filter element
Strainer
Bypass valve
Specifications
Tank capacity: 335 l
Amount of oil inside tank: 248 l
Pressure valve
Relief cracking pressure:
16.7 6.9 kPa {0.17 0.07 kg/cm2}
Suction cracking pressure:
0 0.49 kPa {0 0.005 kg/cm2}
Exhaust valve set pressure:
150 30 kPa {1.5 0.3 kg/cm2}
Breather
Intake valve set pressure:
2.0 0.3 kPa {0.02 0.003 kg/cm2}
Exhaust valve set pressure:
98 14.7 kPa {1.0 0.15 kg/cm2}
PC400, 450-7E0
PC400, 450-7E0
SEN03588-00
SEN03588-00
Hydraulic pump
Type: HPV160+160 (190)
PC400, 450-7E0
SEN03588-00
Outline
q
This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
EPC valve and variable volume valve.
BMP: Breather installation port
IM: PC mode selector current
ISIG: LS set pressure selector current
OCP: Oil level pickup port
PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PEPC: EPC basic pressure port
PEPB: EPC basic pressure pickup port
PFC: Front pump discharge pressure pickup port
PLSCR: LS set selector pressure pickup port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PM: PC mode selector pressure pickup port
PRC: Rear pump discharge pressure pickup port
PS: Pump suction port
1.
2.
3.
4.
5.
6.
7.
Front pump
Rear pump
LS valve
PC valve
LS-EPC valve
PC-EPC valve
Variable volume valve
PC400, 450-7E0
SEN03588-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Front shaft
Cradle
Front case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
End cap
Rear shaft
Rear case
Servo piston
PC valve
PC400, 450-7E0
SEN03588-00
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q
Cylinder block (7) is supported to shaft (1) by
spline (14).
q
Shaft (1) is supported by front and rear bearings (15).
q
Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q
Piston (6) and shoe (5) constitute the spherical
bearing.
q
Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q
Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pressure bearing when it slides.
PC400, 450-7E0
q
q
q
Piston (6) carries out relative movement in the

axial direction inside each cylinder chamber of
cylinder block (7).
Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged
through valve plate (8).
SEN03588-00
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
q
When this happens, rocker cam (4) moves
along cylindrical surface (B), so angle (a)
between center line (X) of rocker cam (4) and
the ax ial di rec tio n of cy li nder b loc k (7)
changes.
q
(a) is named the swash plate angle.
q
q
10
As center line (X) of rocker cam (4) matches

the axial direction of cylinder block (7) (swash
plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7)
becomes 0.
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping
action is not performed. (Actually, however, the
swash plate angle is not set to 0)
With center line (X) of rocker cam (4) at a

swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder
block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suctioned.
PC400, 450-7E0
SEN03588-00
Control of pump delivery

q
If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q
Servo piston (12) is used for changing swash
plate angle (a).
q
Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q
This linear movement is transmitted to rocker
cam (4) through slider (13).
q
Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q
Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q
Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q
The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pressure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC400, 450-7E0
11
SEN03588-00
1. LS valve
PA:
PDP:
PLP:
PLS:
PP:
PPL:
PSIG:
Pump port
Drain port
LS control pressure output port
LS pressure input port
Pump port
Control pressure input port
LS mode selector pilot port
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Piston
Spool
Spring
Seat
Sleeve
Plug
Locknut
Function
q
The LS (load sensing) valve detects the load
and controls the pump delivery.
q
This valve controls main pump delivery (Q)
according to differential pressure (EPLS)[=
PP PLS], called the LS differential pressure
(the difference between main pump pressure
PP and control valve outlet port pressure PLS).
q
Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the control valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
q
The relationship between the LS differential
pressure between the main pump pressure
(PP) and LS pressure (PLS) (EPLS) [= (PP)
(PLS)] and the pump delivery (Q) changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q
As (ISIG) changes from 0 to 1A, setting force
of the spring also changes. As the result, the
specified median of the pump delivery selector
point changes in the range of 1.18 to 2.65 MPa
{12 to 27 kg/cm2}.
12
PC400, 450-7E0
SEN03588-00
Operation
1) When the control valve is situated at neutral
q
q
The LS valve is a 3-way selector valve, with

pressure (PLS) (LS pressure) from the outlet
port of the control valve brought to spring
chamber (B), and main pump discharge pressure (PP) brought to port (H) of sleeve (8).
Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G)
also changes the position of spool (6). (Setting
force of the spring is changed)
Before the engine is started, servo piston (12) is
pushed to the left. (See the figure to the right.)
If the control lever is at the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit via the control valve spool)
Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
PC400, 450-7E0
q
q
q
Pump pressure (PP) is conducted to the larger

diameter end from the port (K).
The same pump pressure (PP) is conducted to
the smaller diameter end from the port (J).
According to the difference in the areas on
servo piston (12), the pressure moves in to the
direction of minimizing the swash plate angle.
13
SEN03588-00
2) Action for the direction of maximizing the pump delivery
14
When the difference between the main pump

pressure (PP) and LS pressure (PLS), in other
words, LS differential pressure (EPLS)
becomes smaller (for example, when the area
of opening of the control valve becomes larger
and pump pressure PP drops), spool (6) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the
pump delivery larger.
If the output pressure of the EPC valve for the

LS valve enters port (G), rightward force is
generated on piston (7).
If piston (7) is pushed to the right, setting force
of spring (4) is weakened, changing the LS differential pressure (EPLS) [Difference between
oil pressures (PLS) and (PP)] when ports (D)
and (E) of spool (6) are connected.
PC400, 450-7E0
SEN03588-00
3) Action for the direction of minimizing the pump delivery
When LS differential pressure (EPLS) becomes

larger (for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises) because of the rightward
move (it reduces pump delivery) of servo piston
(12), pump pressure (PP) pushes spool (6) to the
right.
When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the right.
As the result, the servo piston (12) moves into
the direction of reducing the swash plate
angle.
As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
PC400, 450-7E0
15
SEN03588-00
4) When servo piston is balanced
16
Let us take the area receiving the pressure at

the large diameter end of the piston as (A1),
the area receiving the pressure at the small
diameter end as (A0), and the pressure flowing
into the large diameter end of the piston as
(PEN).
If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relationship is (A0) (PP) = (A1) (PEN), servo piston (12) will stop in that position.
And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the
same.]
At this point, the relationship between the pressure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
Force of spring (4) is adjusted so that the balanced stop position of this spool (6) may be
determined when (PP) (PLS) = 2.65 MPa {27
kg/cm2} at the specified median.
If (PSIG) [Output pressure of LS-EPC valve
ranging from 0 to 2.9 MPa {0 to 30 kg/cm2}] is
applied to port (G), the balanced stop position
changes in proportion to (PSIG) pressure in
the range of (PP) (PLS) = 1.18 to 2.65 MPa
{12 to 27kg/cm2}.
PC400, 450-7E0
SEN03588-00
2. PC valve
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1.
2.
3.
4.
5.
6.
7.
8.
Plug
Servo piston assembly
Pin
Spool
Retainer
Seat
Cover
Wiring
Function
q
When the pump discharge pressure (PP1)
(self-pressure) and (PP2) (other pump pressure) are high, the PC valve controls the pump
so that the volume of oil beyond the discharge
pressure-based specific flowrate may not be
conducted however you may increase the control valve stroke. Namely it is intended at controlling the horse power for the pumps so that it
may not exceed the engine hose power.
q
If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump delivery.
q
And if the pump discharge pressure goes low,
it increases the pump delivery.
q
In this case, relation between the mean discharge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q)
will becomes as shown in the diagram if the
relation is represented as the parameter the
current value (X) to be given to PC-EPC valve
solenoid.
q
The controller continues counting the actual
engine speed.
q
If the engine speed is slowed down due to
increased load, the controller reduces the
pump delivery to recover the speed.
If the engine speed goes below the specified

value because of increased load, the controller
sends a command current to PC-EPC valve
solenoid in order to reduce the slope angle in
proportion to reduction in the engine speed.
PC400, 450-7E0
17
SEN03588-00
Operation
1) When pump controller is normal
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1)

q
Command current (X) is being sent to PC-EPC
valve solenoid (1) from the pump controller.
q
This command current acts on PC-EPC valve
to output the signal pressure in order to modify
the force pushing piston (2).
q
Spool (3) stops at a position where the combined spool-pushing force is balanced by the
setting force of springs (4) and (6) as well as
the pump pressures (PP1) (self pressure) and
(PP2) (another pump's pressure).
q
The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q
The size of command current (X) is determined
by the nature of the operation (lever operation), the selected working mode, and the set
value and actual value of the engine speed.
18
Other pump's pressure denotes the pressure

of the pump situated on the opposite side.
For the front pump pressure, the other pump's
pressure is that of the rear pump.
And for the rear pump pressure, the other
pump's pressure is that of the front pump.
PC400, 450-7E0
PC400, 450-7E0
SEN03588-00
19
SEN03588-00
Action of spring
q
Load of springs (4) and (6) on the PC valve is
determined by the swash plate position.
q
As servo piston (9) moves to right, spring (6) is
retracted.
q
If the servo piston moves further, it will be contacted again seat (5) and spring (6) will be
fixed.
q
After that, spring (4) alone will operate.
q
The spring load is changed by servo piston (9)
as it extends or compresses springs (4) and
(6).
q
If the command current (X) to PC-EPC valve
solenoid (1) changes, so does the force pushing piston (2).
q
Spring load of springs (4) and (6) is also
affected by the command current (X) to PCEPC valve solenoid.
q
Port (C) of the PC valve is connected to port
(E) of the LS valve.
q
Self pressure (PP1) enters port (B) and the
small diameter end of servo piston (9), and
other pump pressure (PP2) enters port (A).
20
q
q
When pump pressures (PP1) and (PP2) are

small, spool (3) will be positioned in the left
side.
Port (C) and (D) are connected, and the pressure entering the LS valve becomes drain
pressure (PT).
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes
drain pressure (PT), and servo piston (9)
moves to the left side.
The pump delivery will be set to the increasing
trend.
Accompanied with move of servo piston (9),
springs (4) and (6) will be expanded and the
spring force becomes weaker.
As the spring force is weakened, spool (3)
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are connected.
PC400, 450-7E0
SEN03588-00
As a result, the pressure on port (C) rises and

the pressure on the large diameter end of the
piston also rises. Thus, the leftward move of
servo piston (9) is stopped.
Servo piston (9) stop position (= Pump delivery) is decided by the position where the pushing force generated from the pressures (PP1)
and (PP2) applied to spool (3), the pushing
force of the solenoid in PC-EPC valve generates and the pushing force of springs (4) and
(6) are balanced.
PC400, 450-7E0
21
SEN03588-00
(2) When the load on actuator is large and pump discharge pressure is high
Outline
q
When the load is large and pump discharge
pressures (PP1) and (PP2) are high, the force
pushing spool (3) to the right becomes larger
and spool (3) will be moved to the position
shown in above figure.
q
Part of the pressure to be conducted from port
(C) to LS valve flows from port (B) to port (C)
and (D) through LS valve. At the end this flow,
level of this pressure becomes approximately
half of the main pump pressure (PP2).
22
Operation
q
When port (E) and port (G) of the LS valve are
connected, this pressure from port (J) enters
the large diameter end of servo piston (9),
stopping servo piston (9).
q
If main pump pressure (PP2) increases further
and spool (3) moves further to the right, main
pump pressure (PP1) flows to port (C) and acts
to make the pump delivery the minimum.
q
When servo piston (9) moves to the right,
springs (4) and (6) are compressed and push
back spool (3).
q
When spool (3) moves to the left, the opening
of port (C) and port (D) becomes larger.
q
As a result, the pressure on port (C) (= J) is
decreased and the rightward move servo piston (9) is stopped.
q
The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.
PC400, 450-7E0
SEN03588-00
The relationship between the average pump

pressure (PP1 + PP2)/2 and servo piston (9) in
terms of their positions can be represented by
the broken line in the figure springs (4) and (6)
form the double springs.
The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the average pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.
PC400, 450-7E0
23
SEN03588-00
2) As the emergency pump drive switch is turned on due to failure on the pump controller
(1) When the main pump is under light load
q
q
24
If there is a failure in the pump controller, the

emergency pump drive switch is turned on to
hand the control to the resistor side.
In this case, the power is directly supplied from
the battery. The current, however, is too large
as is, so the resistor is set in between to control the current flowing to PC-EPC valve solenoid (1).
The current becomes constant, so the force
pushing piston (2) is also constant.
If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pressure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the left.
At this point, port (C) is connected to the drain
pressure of port (D), and the large diameter
end of the piston of servo piston (9) also
becomes the drain pressure (PT) through the
LS valve.
Since the pressure on the small diameter end

of the piston large, servo piston (9) moves in
the direction to make the discharge amount
larger.
PC400, 450-7E0
SEN03588-00
(2) When the main pump is under heavy load
q
q
If the emergency pump drive switch is turned

on In the same way as in above, the command
current (X) sent to PC-EPC valve solenoid (1)
becomes constant.
For this reason, the force of piston (2) pushing
spool (3) is constant.
If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the diagram above.
In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the diagram corresponding to the current sent to the PC-EPC
valve solenoid through the resistor.
PC400, 450-7E0
The curve resulting when the emergency pump

drive switch is ON is situated further to the left (B)
than when the pump controller is normal (A).
25
SEN03588-00
3. LS(PC)-EPC valve
C : To LS (PC) valve
P : From self pressure reducing valve
T : To tank
1.
2.
3.
4.
5.
6.
7.
26
Connector
Coil
Body
Spring
Spool
Rod
Plunger
PC400, 450-7E0
Function
q
The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion.
q
When it receives signal current (i) from the
controller, it generates the EPC output pressure in proportion to the size of the signal, and
outputs it to the LS (PC) valve.
SEN03588-00
Operation
1) When signal current is 0

(coil is de-energized)
q
q
q
PC400, 450-7E0
When there is no signal current flowing from

the controller to coil (2), coil (2) is de-energized.
Spool (5) is pushed to the left by spring (4).
Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).
27
SEN03588-00
2) When signal current is very small

(coil is energized)
q
q
q
q
q
q
28
When a very small signal current flows to coil

(2), coil (2) is energized, and a propulsion force
is generated on the right side of plunger (7).
Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C).
Pressures on port (C) increases and the force
to act on spool (5) surface and the spring load
on spring (4) become larger than the propulsion force of plunger (7).
Spool (5) is pushed to the left, and port (P) is
shut off from port (C).
Port (C) and port (T) are connected.
Spool (5) moves so that the propulsion force of
plunger (7) may be balance with pressure of
port (C) + spring load of spring (4).
The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in proportion to the size of the signal current.
3) When signal current is maximum

(coil is energized)
q
q
q
q
As the signal current flows to coil (2), coil (2) is

energized.
When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(7) is also at its maximum.
Spool (5) is pushed toward right side by rod
(6).
The maximum volume of pressurized oil is
conducted from port (P) to port (C), increasing
the circuit pressure across EPC valve and LS
(PC) valve to the maximum level.
Since port (T) is closed, pressurized oil does
not flow to the tank.
PC400, 450-7E0
SEN03588-00
4. Variable volume valve
C: To PC valve
P: From self pressure reducing valve
T: To tank
1.
2.
3.
4.
Plug
Block
Piston
Spring
Function
q
The variable volume valve stabilizes the EPC
valve's output pressure.
Operation
Output pressure from EPC valve is conducted
to port (C) and as the result propulsion force of
piston (3) is increased by the load of spring (4).
q
Piston (3) is pushed to the left, and volume of
port (C) is increased.
q
The propulsion force of piston (3) becomes
smaller than the load of spring (4).
q
Piston (3) is pushed toward right, and volume
of port (C) is decreased.
q
PC400, 450-7E0
29
SEN03588-00

2008 KOMATSU
All Rights Reserved
30
SEN03589-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0


Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 26
Functions and operation by valve ................................................................................................................. 30
Merge-divider valve....................................................................................................................................... 47
Attachment circuit selector valve .................................................................................................................. 72
Holding valve ................................................................................................................................................ 74
PC400, 450-7E0
SEN03589-00
Control valve
Outline
q
The control valve consists of a 7-spool valve (6spool valve + boom Hi, arm Hi valve) and a set
of service valves and bottom dump valve. A
merge-divider valve, a back pressure valve, a
boom drift preventive valve are installed to it.
q
Since all the valves are assembled together
with connecting bolts and their passes are connected to each other inside the assembly, the
assembly is compact and easy to maintain.
q
With one spool provided for one work equipment, this control valve is simple in construction.
A1: To bucket cylinder bottom
A2: To L.H. travel motor
A3: To boom cylinder bottom
A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To boom cylinder bottom
A-2: To attachment 1
B1: To bucket cylinder head
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To arm cylinder bottom
B-2: To attachment 1
BP1: Boom raising PPC output pressure
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve
P1: From bucket PPC and EPC valves
P3: From L.H. travel PPC valve
P5: From boom PPC and EPC valves
P7: From swing PPC and EPC valves
P9: From R.H. travel PPC valve
P11: From arm PPC and EPC valves
P-3: From service 1 PPC valves
PLS1: To front pump control

PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PP1S: Pressure sensor mounting port
PPS1: To front pump control
PPS2: To rear pump control
PR: To solenoid valve, PPC valve, and EPC valve
PS: From merge-divide solenoid valve
PST: From travel junction valve solenoid valve
PX1: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: To swing motor S-port (suction side)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6-spool valve
Cover A
Cover B
Boom Hi and arm Hi valve
Service valve 1
Service valve 2
Merge-divider valve
Boom drift preventive valve
Quick return valve
Boom Hi valve check valve
PC400, 450-7E0
SEN03589-00
General view
PC400, 450-7E0
SEN03589-00
Sectional view
(1/5)
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
SEN03589-00
Pressure compensation valve (Arm OUT)

Pressure compensation valve (R.H. travel
REVERSE)
Pressure compensation valve (LEFT swing)
Pressure compensation valve (Boom RAISE)
Pressure compensation valve (L.H. travel
REVERSE)
Pressure compensation valve (Bucket DUMP)
Pressure compensation valve (Boom Hi
RAISE)
Variable pressure compensation valve (Service 1)
Pressure compensation valve (Arm Hi IN)
Pressure compensation valve (Bucket CURL)
FORWARD)
Pressure compensation valve (Boom LOWER)
Pressure compensation valve (RIGHT swing)
FORWARD)
Pressure compensation valve (Arm IN)
Main relief valve
Unload valve
Unload valve
Main relief valve
Spool (Service 2)
Spool (Service 1)
Spool (Boom Hi)
Spool (Bucket)
Spool (L.H. travel)
Spool (Boom)
Spool (Swing)
Spool (R.H. travel)
Spool (Arm)
Spool (Arm Hi)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
54.2 34.8
51.2
417 N
{42.5 kg}
333 N
{34.0 kg}
32 Spool return spring
54.5 34.8
51.2
393 N
{40.1 kg}
315 N
{32.1 kg}
54.6 34.8
51.2
421 N
{42.9 kg}
336 N
{34.3 kg}
54.9 24.2
52.0
251 N
{25.6 kg}
201 N
{20.5 kg}
57.2 22.8
51.0
417 N
{42.5 kg}
333 N
{34.0 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
SEN03589-00
(2/5)
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
SEN03589-00
Suction safety valve (Arm OUT)

Suction valve (Right travel REVERSE)
Suction valve (Boom RAISE)
Suction valve (Left travel REVERSE)
Suction valve (Boom Hi RAISE)
Suction safety valve (Service 1)
2-stage suction safety valve (Service 1)
Suction safety valve (Arm Hi IN)
Suction safety valve (Bucket CURL)
Suction valve (Left travel FORWARD)
2-stage suction safety valve (Boom LOWER)
Suction valve (Right travel FORWARD)
Suction safety valve (Arm IN)
LS shuttle valve (Arm)
LS shuttle valve (Right travel)
LS select valve
LS shuttle valve (Boom)
LS shuttle valve (Left travel)
LS shuttle valve (Bucket)
LS shuttle valve (Service 1)
LS check valve
Pressure relief plug
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
25 Suction valve spring
26 Check valve spring
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
40.6
5.5 N
{0.56 kg}
4.4 N
{0.45 kg}
46.8 7.5
11.5 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
If damaged or
deformed, replace
spring.
SEN03589-00
(3/5)
PC400, 450-7E0
1.
2.
3.
4.
SEN03589-00
Unload valve
Safety valve (Boom RAISE)
Main relief valve
Lift check valve
Arm valve
5. LS shuttle valve
6. Pressure compensation valve (IN)
7. Spool
8. Suction safety valve (IN)
9. Regeneration circuit check valve
10. Suction safety valve (OUT)
11. Pressure compensation valve (OUT)
R.H. travel valve
12. LS shuttle valve
13. Pressure compensation valve (FORWARD)
14. Spool
15. Suction valve (FORWARD)
16. Suction valve (REVERSE)
17. Pressure compensation valve (REVERSE)
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
42.0
19.6 N
{2.0 kg}
15.7 N
{1.6 kg}
50.0 14.4
31.5 10.3
19.5
5.9 N
{0.6 kg}
4.71 N
{0.48 kg}
If damaged or
deformed, replace
spring.
SEN03589-00
(4/5)
10
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
SEN03589-00
Return spring
Merge-divide valve (for LS)
Valve (Sequence valve)
Spring (Sequence valve)
Merge-divide valve (Main)
Return spring
Boom valve
7. Drift preventive valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. 2-stage suction safety valve (LOWER)
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve
15. Merge-divider valve (travel junction valve)
16. Return spring
19. Spool
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
46.6 21.8
33.0
157 N
{16.0 kg}
126 N
{12.8 kg}
70.9 18.0
56.0
250 N
{25.5 kg}
200 N
{20.4 kg}
64.5 32.3
63.0
178 N
{18.1 kg}
142 N
{14.5 kg}
33.0 12.0
26.0
35.3 N
{3.6 kg}
28.2 N
{2.88 kg}
16.4 8.9
11.5
13.7 N
{1.4 kg}
11.0 N
{1.12 kg}
31.5 10.3
19.5
5.9 N
{0.6 kg}
4.71 N
{0.48 kg}
35 Piston return spring
30.7 20.5
23.0
50.0 N
{5.1 kg}
40.0 N
{4.08 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
11
SEN03589-00
(5/5)
12
PC400, 450-7E0
SEN03589-00

1.
2.
3.
4.
5.
6.
7.
8.
Boom Hi check valve

Quick return valve
Arm Hi spool
Boom Hi spool
Pressure compensation valve (Boom
RAISE)
Hi
Service valve 1
9. LS shuttle valve
10. Pressure compensation valve
11. Spool
12. 2-stage suction safety valve
13. Suction safety valve
Service valve 2
16. Spool
18. Unload valve
19. Main relief valve
20. LS bypass plug
PC400, 450-7E0
13
SEN03589-00

A1: To bucket cylinder bottom
A2: To L.H. travel motor
A3: To boom cylinder bottom
A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To boom cylinder bottom
A-3: To bottom dump cylinder head
B1: To bucket cylinder head
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To arm cylinder bottom
B-3: To bottom dump cylinder bottom
BP1: Boom raising PPC output pressure
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve
P-5: From bottom dump PPC valves
P-6: From bottom dump PPC valves
PLS1: To front pump control
PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PPS1: To front pump control
PPS2: To rear pump control
PR: To solenoid valve, PPC valve, and EPC valve
PS: From merge-divide solenoid valve
PST: From travel junction valve solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: To swing motor S-port (suction side)
14
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6-spool valve
Cover A
Cover B
Service valve 1
Bottom dump valve
Merge-divider valve
Quick return valve
Boom Hi valve check valve
PC400, 450-7E0
SEN03589-00
General view
PC400, 450-7E0
15
SEN03589-00
Sectional view
(1/5)
16
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
SEN03589-00
Pressure compensation valve (Arm OUT)

REVERSE)
Pressure compensation valve (LEFT swing)
Pressure compensation valve (Boom RAISE)
REVERSE)
Pressure compensation valve (Bucket DUMP)
Pressure compensation valve (Boom Hi
RAISE)
Compensation valve (Bottom dump)
Pressure compensation valve (Bucket CURL)
FORWARD)
Pressure compensation valve (Boom LOWER)
Pressure compensation valve (RIGHT swing)
FORWARD)
Pressure compensation valve (Arm IN)
Main relief valve
Unload valve
Unload valve
Main relief valve
Spool (Bottom dump)
Spool (Service 1)
Spool (Boom Hi)
Spool (Bucket)
Spool (L.H. travel)
Spool (Boom)
Spool (Swing)
Spool (R.H. travel)
Spool (Arm)
Spool (Arm Hi)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
54.2 34.8
51.2
417 N
{42.5 kg}
333 N
{34.0 kg}
54.5 34.8
51.2
393 N
{40.1 kg}
315 N
{32.1 kg}
54.6 34.8
51.2
421 N
{42.9 kg}
336 N
{34.3 kg}
54.9 24.2
52.0
251 N
{25.6 kg}
201 N
{20.5 kg}
57.2 22.8
51.0
417 N
{42.5 kg}
333 N
{34.0 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
17
SEN03589-00
(2/5)
18
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
SEN03589-00
Suction safety valve (Arm OUT)

Suction valve (Right travel REVERSE)
Suction valve (Boom RAISE)
Suction valve (Left travel REVERSE)
Suction safety valve (Bottom dump)
2-stage suction safety valve (Service 1)
Suction safety valve (Bucket CURL)
Suction valve (Left travel FORWARD)
2-stage suction safety valve (Boom LOWER)
Suction valve (Right travel FORWARD)
Suction safety valve (Arm IN)
LS shuttle valve (Arm)
LS shuttle valve (Right travel)
LS select valve
LS shuttle valve (Boom)
LS shuttle valve (Left travel)
LS shuttle valve (Bucket)
LS shuttle valve (Bottom dump)
LS check valve
Pressure relief plug
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
25 Suction valve spring
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
40.6
5.5 N
{0.56 kg}
4.4 N
{0.45 kg}
46.8 7.5
11.5 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
If damaged or
deformed, replace
spring.
19
SEN03589-00
(3/5)
20
PC400, 450-7E0
1.
2.
3.
4.
SEN03589-00
Unload valve
Safety valve (Boom RAISE)
Main relief valve
Lift check valve
Arm valve
5. LS shuttle valve
6. Pressure compensation valve (IN)
7. Spool
8. Suction safety valve (IN)
10. Suction safety valve (OUT)
11. Pressure compensation valve (OUT)
R.H. travel valve
14. Spool
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
42.0
19.6 N
{2.0 kg}
15.7 N
{1.6 kg}
50.0 14.4
31.5 10.3
19.5
5.9 N
{0.6 kg}
4.71 N
{0.48 kg}
If damaged or
deformed, replace
spring.
21
SEN03589-00
(4/5)
22
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
SEN03589-00
Return spring
Merge-divide valve (for LS)
Valve (Sequence valve)
Spring (Sequence valve)
Merge-divide valve (Main)
Return spring
Boom valve
7. Drift preventive valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. 2-stage suction safety valve (LOWER)
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve
15. Merge-divider valve (travel junction valve)
16. Return spring
19. Spool
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
46.6 21.8
33.0
157 N
{16.0 kg}
126 N
{12.8 kg}
70.9 18.0
56.0
250 N
{25.5 kg}
200 N
{20.4 kg}
64.5 32.3
63.0
178 N
{18.1 kg}
142 N
{14.5 kg}
33.0 12.0
26.0
35.3 N
{3.6 kg}
28.2 N
{2.88 kg}
16.4 8.9
11.5
13.7 N
{1.4 kg}
11.0 N
{1.12 kg}
31.5 10.3
19.5
5.9 N
{0.6 kg}
4.71 N
{0.48 kg}
35 Piston return spring
30.7 20.5
23.0
50.0 N
{5.1 kg}
40.0 N
{4.08 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
23
SEN03589-00
(5/5)
24
PC400, 450-7E0
SEN03589-00

1.
2.
3.
4.
5.
6.
7.
8.
Boom Hi check valve

Quick return valve
Arm Hi spool
Boom Hi spool
Pressure compensation valve (Boom
RAISE)
Hi
Service valve 1
9. LS shuttle valve
11. Spool
Bottom dump valve
16. Spool
18. Unload valve
19. Main relief valve
20. LS bypass plug
PC400, 450-7E0
25
SEN03589-00
CLSS
Outline of CLSS
Features
CLSS stands for Closed center Load Sensing System, which has the following characteristics:
q
q
q
26
Fine control not influenced by load

Controllability enabling digging even with fine
control
Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
Energy saving using variable pump control
Configuration
q
CLSS is configured with variable capacity piston pumps, control valves, and respective
actuators.
q
The hydraulic pump is configured with pump
body, PC valve and LS valve.
PC400, 450-7E0
SEN03589-00
Basic principle
1.
q
Pump swash plate angle control

The pump swash plate angle (pump delivery)
is controlled so that LS differential pressure
(EPLS) (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is
constant.
[LS differential pressure (EPLS) = Pump discharge pressure (PP) LS pressure (PLS)]
The pump swash plate angle shifts toward the

maximum position if LS differential pressure
(EPLS) is lower than the set pressure of the
LS valve (when the actuator load pressure is
high). If it becomes higher than the set pressure (when the actuator load pressure is low),
the pump swash plate angle shifts toward the
minimum position.
If it becomes higher than the set pressure
(when the actuator load pressure is low), the
pump swash plate angle shifts toward the minimum position.
LS differential pressure ( E PLS) and pump

swash plate angle
PC400, 450-7E0
For details of functions, see the Hydraulic

pump.
27
SEN03589-00
2.
Pressure compensation control
A pressure compensation valve is installed to

the outlet port side of the control valve to balance the load.
When actuators are operated together, the
p r e s s u r e d i ff e r e n c e ( E P ) b e t w e e n t h e
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pressure).
The flow of oil from the pump is divided (compensated) in proportion to the area of opening
(S1) and (S2) of each valve.
28
PC400, 450-7E0
3.
System diagram
The illustration shows actuator (7) in the merge

mode with stroke end at the time of relief.
1.
2.
3.
4.
5.
6.
7.
8.
Front pump
Rear pump
Main relief valve
Unload valve
Merge-divider valve
Control valve
Actuator
Pump circuit
PC400, 450-7E0
SEN03589-00
9.
10.
11.
12.
13.
14.
15.
LS circuit
Tank circuit
Valve
Spring
LS bypass valve
LS valve
PC valve
29
SEN03589-00
Functions and operation by valve
Hydraulic circuit diagram and the name of valves

30
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Arm valve
R.H. travel valve
Swing valve
Boom valve
L.H. travel valve
Bucket valve
Boom Hi valve
Arm Hi valve
Service valve 1
Service valve 2
Arm spool
R.H. travel spool
Swing spool
Boom spool
L.H. travel spool
Bucket spool
Boom Hi spool
Arm Hi spool
Service spool 1
Service spool 2
Pressure compensation valve
Variable pressure compensation valve
Suction valve
Check valve (for boom regeneration circuit)
Check valve (for arm regeneration circuit)
LS shuttle valve
LS select valve
Merge-divider valve
Arm quick return valve
Self pressure reducing valve
Travel junction valve
Back pressure valve
Boom Hi check valve
Main relief valve (bucket side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
When digging force increased:
37.3 MPa {380 kg/cm2} (190l/min)
Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
Unload valve (bucket side)
Cracking pressure: 3.1 MPa {32 kg/cm2}
Unload valve (arm side)
Suction safety valve
Set pressure: 17.2 0.5 MPa {175 5 kg/cm2}
2-stage suction safety valve
Set pressure: 1 stage: 17.2 0.5 MPa {175 5 kg/cm2}
2 stage: 21.1 0.5 MPa {205 5 kg/cm2}
PC400, 450-7E0
SEN03589-00

2 stage: 28.4 0.5 MPa {290 5 kg/cm2}
43. Safety valve
31
SEN03589-00
32
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Arm valve
R.H. travel valve
Swing valve
Boom valve
L.H. travel valve
Bucket valve
Boom Hi valve
Arm Hi valve
Service valve 1
Bottom dump valve
Arm spool
R.H. travel spool
Swing spool
Boom spool
L.H. travel spool
Bucket spool
Boom Hi spool
Arm Hi spool
Service spool 1
Bottom dump spool
Suction valve
Check valve (for boom regeneration circuit)
Check valve (for arm regeneration circuit)
LS shuttle valve
LS select valve
Merge-divider valve
Arm quick return valve
Back pressure valve
Boom Hi check valve
Main relief valve (bucket side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
Unload valve (bucket side)
Unload valve (arm side)
2 stage: 21.1 0.5 MPa {205 5 kg/cm2}
PC400, 450-7E0
SEN03589-00

2 stage: 28.4 0.5 MPa {290 5 kg/cm2}
43. Safety valve
33
SEN03589-00
Unload valve
1.
When the unload valve is actuating
1.
2.
3.
LS circuit
Valve
Pump circuit
Function
q
Drains an oil discharge for the portion of the
minimum pump swash plate angle while all
control valves are in the holding.
q
The pump pressure will correspond to a set
load of spring (5) inside the valve (this pressure will be P1).
q
Since LS pressure is drained from the LS
bypass valve, LS pressure C tank pressure C
0 MPa {0 kg/cm2}.
34
4.
5.
Tank circuit
Spring
Operation
q
Pressure of pump circuit (3) is received by the
end of valve (2).
q
Since the control valve is in neutral position,
pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
q
Pressurized oil of pump circuit (3) stops at
valve (2), and the pressure rises as no relief is
available.
q
When this pressure becomes larger than the
force of spring (5), valve (2) moves to the left.
q
Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q
The pressurized oil of LS circuit (1) passes
from orifice (a) through port (c) and is drained
to the tank circuit (4).
q
When actuated, LS pressure C tank pressure.
q
Since the pump discharge pressure LS circuit pressure during unloading is larger than
the pump LS control pressure, the signal is
output to minimize the pump swash plate
angle.
PC400, 450-7E0
During operation (a work within a scope of discharge by a minimum swash plate angle), the
discharge pressure for the portion of minimum
pump swash plate angle is set to LS pressure
+ P1 pressure.
LS control differential pressure (EPLS) of discharge for the portion of minimum swash plate
angle will be equal to P1 pressure.
SEN03589-00
2.
q
q
q
q
q
PC400, 450-7E0
Operation of relief valve

When the cylinder reaches the stroke end, the
main relief valve opens.
The pump delivery (Q) is relieved to the
tank.(See the system diagram)
The pump discharge pressure (PP) and LS
pressure (PLS) become approximately the
same as each has not flow at the upstream
and downstream of the spool, and LS differential pressure (EPLS) becomes 0 kg/cm2.
As LS differential pressure (EPLS) is lower
than the LS set pressure of LS valve, LS valve
is actuated to maximize the pump swash plate
angle.
Mechanically, operation of PC valve have the
prevalence to that of LS valve.
The pump is held at a minimum swash plate
angle by the cut-off function of PC valve.
35
SEN03589-00
Introduction of LS pressure
1.
2.
3.
4.
5.
6.
7.
Hydraulic pump
Main spool
Valve
Check valve
LS circuit
LS shuttle valve
Function
q
Introduces the upstream pressure (spool
meter-in downstream pressure) of pressure
compensation valve (3) and leads to LS shuttle
valve (7) as the LS pressure.
q
Connected to actuator port (B) through valve
(4), and makes LS pressure C actuator load
pressure.
q
Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.
Operation
When main spool (2) is operated, the pump
pressure enters port (c) through inlet pore (a)
and is led to the LS circuit.
q
When the pump pressures rises to reach the
load pressure of port (B), check valve (5)
opens and the pressurized oil flows.
q
36
PC400, 450-7E0
SEN03589-00
LS bypass valve
1.
2.
3.
4.
5.
6.
Hydraulic pump
Main spool
LS shuttle valve
LS bypass valve
LS circuit
Function
q
Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q
Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pressure.
q
Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the circuit resistance between throttle (c) of main
spool (2) and LS shuttle valve (4).
q
Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
PC400, 450-7E0
37
SEN03589-00

1.
During independent operation and under maximum load pressure

(If the load pressure is higher than other work equipment during a combined operation)
1.
2.
3.
Hydraulic pump
Valve
Shuttle valve
Function
q
Pressure compensation valve works as the
load check valve.
q
If the pump pressure (LS pressure) is lower
than the load at port (c), shuttle valve (3) in
pressure compensation valve piston (4) interconnects spring chamber (E) and port (C).
q
The force of spring (5) operates piston (4) and
valve (2) to the closing direction.
4.
5.
6.
Piston
Spring
LS shuttle valve
As principle, port (C) and spring chamber (E)

are not interconnected in an integrated pressure compensation valve.
If high peak pressure is generated at port (C),
valve (7) does not collide with the valve chamber.
With a bucket valve, etc., port (C) and spring
chamber (E) are designed to interconnect
before valve (7) is seated.
Integrated pressure compensation valve

High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator circuit or repetitive peak pressure occurs continuously (example: when using the breaker).
q
To prevent this, a pressure compensation
valve with integrated valve (2) and piston (4) is
used.
q
With the present machine, this device is
adopted for the bucket valve (cylinder bottom)
and the service valve.
q
38
PC400, 450-7E0
2.
SEN03589-00
When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
q
The pressure compensation valve closes
under LS pressure of port (D), and the spool
meter-in downstream pressure of port (B)
becomes equivalent to the maximum pressure
of other work equipment.
q
Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meterin differential pressure [upstream pressure port
(A) pressure] downstream pressure [port (B)
pressure] becomes equivalent to all the spools
in operation.
q
Pump flow is divided according to the ratio of
the meter-in opening area.
Operation
q
Spring chamber (E) is interconnected to port
(D).
q
Piston (4) and valve (2) operate in the closing
direction (to the right) under the LS circuit pressure from other work equipment of port (F).
q
Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
PC400, 450-7E0
39
SEN03589-00
3.
Pressure compensation valve area ratio
Function
q
The state of division changes according to the
area ratio of pressure compensation portion
(A1) and (A2). Area ratio = (A2)/(A1)
q
If area ratio = 1 : the spool meter-in downstream pressure will be equal to the maximum
load pressure, and the pressure will be divided
according to the opening area ratio.
q
If area ratio = 1 or over : the spool meter-in
downstream pressure will be greater than the
maximum load pressure, and the pressure will
be divided smaller than the opening area ratio.
q
If area ratio = 1 or under : the spool meter-in
downstream pressure will be smaller than the
maximum load pressure, and the pressure will
be divided greater than the opening area ratio.
40
PC400, 450-7E0
SEN03589-00
Pressure compensation valve inner shuttle valve

1.
If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1.
2.
3.
4.
Hydraulic pump
Valve
Pressure compensation valve inner shuttle valve
Piston
Function
q
Shuttle valve (3) is pushed to the right by port
(A) pressure and cuts off interconnection
between ports (A) and (C).
q
Holding pressure at port (A) is led to the spring
chamber (B) to push piston (4) to the left so
that piston (4) and valve (2) will not be separated.
PC400, 450-7E0
41
SEN03589-00
2.
In the case of travel
Outline
q
Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation valve without shuttle valve (3) is adopted.
42
PC400, 450-7E0
SEN03589-00
Boom regeneration circuit

1.
If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1.
2.
3.
4.
5.
6.
7.
Hydraulic pump
Boom spool
Suction valve
Check valve
LS shuttle valve
Function
Provides the regeneration circuit from the cylinder bottom to the cylinder head when the
boom is lowered and increases flow to the cylinder bottom.
PC400, 450-7E0
Operation
q
If the cylinder head pressure is lower than the
bottom pressure, pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from
the notch of boom spool (2).
q
On the other hand, remaining oil flows to regeneration circuit (C), opens check valve (6) and
flows to the cylinder head through circuit (D).
q
Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
43
SEN03589-00
2.
If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q
Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
44
PC400, 450-7E0
SEN03589-00
Arm regeneration circuit

1.
If the cylinder head pressure is higher than the bottom pressure
1.
2.
3.
4.
5.
6.
7.
Hydraulic pump
Arm spool
Suction valve
Check valve
LS shuttle valve
Function
q
During arm digging, regeneration circuit provided from the cylinder head to the bottom
increases the cylinder speed as the cylinder
flow involves the pump delivery plus regenerated flow.
PC400, 450-7E0
Operation
q
If the cylinder head pressure is higher than the
bottom pressure, pressurized oil (A) from the
cylinder head flows to drain circuit (B) from the
notch of arm spool (2).
q
On the other hand, remaining oil flows to
regeneration circuit (C), opens check valve (6)
and flows to the cylinder bottom through circuit
(D).
q
Flow from regeneration circuit (C) and pump
(1) merges in circuit (E).
45
SEN03589-00
2.
If the cylinder head pressure is lower than the bottom pressure
Function
q
Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to the head.
46
PC400, 450-7E0
Merge-divider valve
SEN03589-00
1.
When flows from the pumps merge [if pilot pressure (PS) is OFF]
1.
2.
3.
4.
Main spool
Spring
LS spool
Spring
Function
q
Merges pressurized oil (P1) and (P2) discharged from the two pumps or divides (to
respective control valve group).
q
Merges and divides LS circuit pressure.
PC400, 450-7E0
5.
6.
7.
8.
LS circuit (bucket side)

LS circuit (bucket side)
LS circuit (arm side)
LS circuit (arm side)
Operation
q
Since pilot pressure (PS) is OFF, output pressure from PPC valve is 0 MPa {0 kg/cm2}.
q
Main spool (1) is pressed to the right by spring
(2) and ports (E) and (F) are interconnected.
q
Merges pressurized oil (P1) and (P2) discharged from the two pumps at ports (E) and
(F) and sends to necessary control valve.
q
Since pilot pressure (PS) is OFF for LS spool
(3), it is pressed to the right by spring (4), and
ports (A) (D) and ports (B) (C) are interconnected.
q
Forwards LS pressure led from respective control valve spools to LS circuits (5), (6), (7) and
(8) to all the pressure compensation valves.
47
SEN03589-00
2.
When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
q
Pilot pressure (PS) turns ON, and output pressure from the PPC valve shifts main spool (1)
to the left, and ports (E) and (F) are divided.
q
Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
q
LS spool (3) too shifts to the left under the output pressure from the PPC valve, interconnects ports (A) and (C) and divides other ports.
q
Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
48
PC400, 450-7E0
SEN03589-00
LS select valve
Function
q
Prevents high LS pressure from the swinging
from entering the LS circuit of work valves
while the swinging and work equipment are in
combined operation.
q
Prevents high pressure generated during
swing drive and improves operability of work
equipment.
Operation
1. If pilot pressure (BP) is OFF
q
Since pilot pressure (BP) is OFF, piston (3) is
pressed to the left by spring (2).
q
When swing-operated, swing LS pressure (P1)
enters port (A) after passing swing spool (5).
q
Valve (1) is pressed to the left and ports (A)
and (B) are interconnected.
q
Swing LS pressure (P1) flows to LS shuttle
valve (8).
2.
q
q
q
q
a
1.
2.
3.
4.
5.
6.
7.
8.
9.
If pilot pressure (BP) is ON

If pilot pressure (BP) is ON, BP pressure contracts spring (2), and piston (3) shifts to the
right.
Valve (1) is pressed to the right and interconnection between ports (A) and (B) is closed.
Swing LS pressure (P1) stops flowing to LS
shuttle valve (8).
If swing LS pressure (P1) rises, other LS circuits are not affected.
The illustration shows the state of simultaneous operation of swinging and R.H. travel.
[(BP) pressure ON]
Valve
Spring
Piston
Piston
Swing spool
L.H. travel spool
Arm spool
LS shuttle valve
LS circuit
PC400, 450-7E0
49
SEN03589-00

Function
q
Reduces the discharge pressure of the main
pump and supplies it as control pressure for
the solenoid valves, EPC valves, etc.
Operation
1. While engine is stopped
q
Poppet (11) is pressed by spring (12) against
the seat and port (PR) is not connected to
(TS).
q
Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
q
Valve (7) is pressed by spring (8) against the
left side and port (P2) is closed to (A2).
50
PC400, 450-7E0
2.
a
During neutral and when load pressure (P2)

is low
When load pressure (A2) is lower than self
pressure reducing valve output pressure (PR)
SEN03589-00
3.
q
q
q
q
q
q
Valve (7) is pressed to the closing direction of

circuit between ports (P2) and (A2) by spring
(8) and under pressure (PR) (which is 0 MPa
{0 kg/cm2}).
When pressurized oil flows in from port (P2), a
balance is reached due to [(d area P2 pressure) = force of spring (8) + (d area PR
pressure)].
Adjusts valve (7) opening to keep pressure
(P2) at a constant level over pressure (PR).
When pressure (PR) rises above the set pressure, poppet (11) opens.
Pressurized oil flows from port (PR) to orifice
(a) in spool (14), then flows to seal drain port
(TS) from poppet (11) opening.
Differential pressure is generated before and
after orifice (a) in spool (14) and then spool
(14) moves to close the pass between ports
(P2) and (PR).
Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the
set pressure) and supplied as pressure (PR).
PC400, 450-7E0
q
q
When load pressure (P2) is high

Load pressure (A2) increases with the operation of digging, etc, and the pump discharge
increases accordingly.
Pressure (P2) increases to [(d area P2
pressure) = force of spring (8) + (d area PR
pressure)], and valve (7) moves to the right to
the stroke end.
As a result, opening between ports (P2) and
(A2) increases, and the pass resistance
reduces, reducing the engine horsepower loss.
When pressure (PR) rises above the set pressure, poppet (11) opens.
Pressurized oil flows from port (PR) to orifice
(a) in spool (14), then flows to seal drain port
(TS) from poppet (11) opening.
Differential pressure is generated before and
after orifice (a) in spool (14) and then spool
(14) moves to close the pass between ports
(P2) and (PR).
Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the
set pressure) and supplied as pressure (PR).
51
SEN03589-00
4.
q
q
q
52
When abnormally high pressure is generated

If pressure (PR) of self pressure reducing
valve becomes abnormally high, ball (16) contracts spring (15) and becomes separated from
the seat.
Allows the pressurized oil to (TS) from port
(PR) and lowers pressure (PR).
Protects PPC valve, solenoid valve and other
devices from abnormal pressure.
PC400, 450-7E0
SEN03589-00

1.
When pilot pressure is turned ON
Function
q
This valve connects the L.H. and R.H. travel
circuits through travel junction valve so that the
hydraulic oil will be supplied evenly to both
travel motors to improve machine's straight
travel performance.
q
When the machine is steered, outside pilot
pressure (PST) closes the travel junction valve
to improve steering performance.
PC400, 450-7E0
Operation
q
Pilot pressure (PST) from the travel junction
solenoid valve compresses spring (1), and
travel junction spool (2) moves to the left to the
stroke end.
q
Junction circuit between port (PTL) (L.H. travel
circuit) and port (PTR) (R.H. travel circuit) is
closed.
53
SEN03589-00
2.
When pilot pressure is turned OFF
Operation
q
If pilot pressure (PST) from the solenoid valve
is 0 MPa {0 kg/cm2}, travel junction spool (2) is
pressed to the right side by the force of spring
(1) and the passage between ports (PTL) and
(PTR) is opened.
54
If the oil flow rates to the L.H. and R.H. travel

motors become different from each other, the
oil flows through the route between port (PTL),
travel junction spool (2), and port (PTR) so that
the oil flow rates to both motors will be equalized again.
PC400, 450-7E0
SEN03589-00
Travel PPC shuttle valve

1.
When travel lever is in neutral
Function
q
Regulates flow to each cylinder by controlling
the stroke of each spool of the boom, arm, and
bucket using the pilot pressure of travel PPC
valve while climbing a steep grade, raising the
boom, digging with arm, dumping, bucket-digging or operating dump.
q
When controlling the stroke of the boom, arm
and/or bucket, pilot pressure of travel PPC
valve passes through the circuit inside the control valves to actuate the system.
PC400, 450-7E0
Operation
q
The oil in stroke regulation signal chamber (a)
is drained through orifices (5) and (6) of pistons (3) and (4) in the travel spring case and
the travel PPC valve.
q
When operated for boom raising (or arm digging, dumping, bucket digging, dumping),
spool (1) moves to the left until it makes contact with the end face of spring casing (2) (st0).
55
SEN03589-00
2.
When traveling
Operation
q
If the right travel lever is set in the reverse (or
forward) direction, pilot pressure from the PPC
valve presses spool (7) to the left (or right).
q
Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber
(a) and the drain circuit of the travel PPC
valve.
q
At this time, the right travel reverse (or forward)
lever is set, pilot pressure from the PPC valve
is applied through orifice (6) of piston (4) to the
left end of piston (8) to push piston (8) to the
right.
56
When operated for boom raising (or arm in,

out, bucket curl, dump), spool (1) moves to the
left.
Maximum stroke of the spool is limited to (st1)
for the amount of movement (st2) of piston (8)
to the right.
PC400, 450-7E0
SEN03589-00

1.
When raising boom
Function
q
This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.
Operation
q
When the boom is raised, pressurized oil from
the control valve works on the ring-shaped
area (S)[= (d1) area (d2) area] caused by
the difference between outside diameter (d1)
of poppet (5) and seat diameter (d2) to move it
to the left.
q
Contracts spring (4) and poppet (5) moves to
the left.
q
As a result, pressurized oil from the control
valve passes through the opening of poppet
(5) and flows to the bottom end of the boom
cylinder.
PC400, 450-7E0
57
SEN03589-00
2.
When the boom is in neutral
Operation
q
Moves the lever to neutral with the boom
raised.
q
Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q
Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
q
The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by
the difference between outside diameter (d1)
of poppet (5) and seat diameter (d2) to move it
to the right.
q
The sum of this force and the force of spring
(4) closes poppet (5).
q
holding pressure of the boom cylinder bottom
are shut off.
58
PC400, 450-7E0
3.
SEN03589-00
When lowering boom
Operation
q
When the boom is lowered, pilot pressure from
the PPC valve presses pilot piston (2).
q
Pressurized oil in chamber (b) inside the poppet is drained through orifice (c).
q
Pressurized oil of the boom bottom flows to orifice (a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q
As the pressure of chamber (b) lowers under
the pressure of port (B), poppet (5) opens.
q
Pressurized oil from port (B) is led to port (A)
and then flows to the control valve.
PC400, 450-7E0
59
SEN03589-00
Arm drift preventive valve

(if equipped)
1.
When arm OUT
Function
q
This valve prevents the oil in the arm head
from leaking through spool (1) and the boom
from lowering under its weight while the arm
lever is not operated.
Operation
q
When the arm OUT is operated, pressurized
oil from the control valve works on the ringshaped area (S) [= (d1) area (d2) area]
caused by the difference between the outside
diameter (d1) of poppet (5) and the seat diameter (d2) to move it to the left.
q
Contracts spring (4) and poppet (5) moves to
the left.
q
As a result, pressurized oil from the control
valve passes through the opening of poppet
(5) and flows to the arm cylinder head.
60
PC400, 450-7E0
2.
SEN03589-00
When the arm is in neutral
Operation
q
Moves the lever to neutral with the arm
dumped.
q
Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
q
holding pressure of the arm cylinder head are
shut off.
q
The holding pressure of arm cylinder head
works on ring-shaped area (S) caused by the
difference between outside diameter (d1) of
poppet (5) and seat diameter (d2) to move it to
the right.
q
The sum of this force and the force of spring
(4) closes poppet (5).
q
holding pressure of the arm cylinder head are
shut off.
PC400, 450-7E0
61
SEN03589-00
3.
When arm IN
Operation
q
If arm is set to IN, pilot piston (2) is pushed by
the pilot pressure from the PPC valve.
q
Pressurized oil in chamber (b) inside the poppet is drained through orifice (c).
q
Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q
As the pressure of chamber (b) lowers under
the pressure of port (B), poppet (5) opens.
q
Pressurized oil from port (B) is led to port (A)
and then flows to the control valve.
62
PC400, 450-7E0
4.
When abnormally high pressure is generated
If abnormally high pressure is generated in the

boom cylinder bottom circuit, the pressurized
oil in port (B) pushes check valve (6) open,
then safety valve (3) operates.
PC400, 450-7E0
SEN03589-00
If arm drift preventive valve (If equipped) is

installed to the arm cylinder head circuit, the
boom cylinder bottom circuit pressure force or
arm cylinder head circuit pressure force,
whichever having higher pressurized oil,
pushes check valve (6) or (6A) open to actuate
safety valve (3).
63
SEN03589-00
Quick return valve

1.
When arm OUT
Function
q
When arm is set to out, large volume of oil
returns from the cylinder bottom.
q
Reduces this pressure loss.
Operation
q
When arm is set to out, pilot piston (1) is
pushed by the pilot spool from the PPC valve.
q
Pressurized oil in chamber (b) inside the valve
is drained through orifice (c).
q
Pressurized oil of the arm bottom side flows to
orifice (a) o chamber (b) o orifice (c) o drain
(T), and the pressure in chamber (b) lowers.
q
If the pressure of chamber (b) drops lower than
that of port (A), pressure receiving force of the
pressure receiving portion [d2 area (S2)
(seat diameter area)] on the side of port (A)
increases by the sum of the pressure receiving
force of pressure receiving portion[d1 area
(S1)] on the chamber (b) side of valve (2) and
the spring force.
64
q
q
q
Or (d2 pressure receiving force > d1 pressure receiving force + spring force)
Valve (2) is pressed to the left and pressurized
oil is led from port (A) to (B).
From port (B), pressurized oil is drained
directly to the tank.
PC400, 450-7E0
2.
SEN03589-00
When the arm is in neutral
Operation
q
Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0 kg/
cm2}.
q
The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
q
The holding pressure on the arm bottom side
works on the difference between areas (S2)
and (S1) of valve (2) to the right.
q
Valve (2) is closed by the total of this force and
the force of spring (3), so ports (A) and (B) are
shut off.
PC400, 450-7E0
65
SEN03589-00
Lift check valve

Function
q
This valve applies back pressure to the drain
circuit to prevent generation of negative pressure on each actuator (motors, cylinders, etc.).
Operation
1. While engine is stopped
q
Pressurized oil is not fed to the self pressure
reducing valve from the pump, and valve (1) is
pressed to the right by the force of spring (2).
q
Drain circuit (a) of the control valve is connected with port (T) through orifice (b) of valve
(1).
2. While engine is running

q
Output pressure (PR) of the self pressure

reducing valve is conducted to through the
control valve to spring chamber (c) of lift check
valve (3).
Output pressure (PR) applied to spring chamber (c) is applied to the left end of valve (1)
(area of d) to push valve (1) to the right.
At this time, pressure (PA) of drain circuit (a) of
the control valve is applied to the right end of
valve (1) (area of d1) to push valve (1) to the
left.
Valve (1) strikes balance to make the back
pressure equal to (PA) in the equation below.
PA =
66
(Area of d) PR + force of spring (2)

Area of d1
PC400, 450-7E0
SEN03589-00
Main relief valve
1.
2.
Spring
Poppet
Function
q
Set pressure of the relief valve is in two stages.
q
When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes
higher.
Operation
The set pressure of relief valve is determined
by spring (1) installed load. (1st stage)
q
Respective setting is not required for both the
1st and 2nd stages. Setting the 1st stage completes the setting of the 2nd stage.
q
1.
If pilot pressure (P) is OFF: Low-pressure

setting
Set pressure is determined by spring (1)
installed load.
2.
If pilot pressure (P) is ON: High-pressure

setting
Spring (1) installed load is added with pilot
pressure (P) applied to the area of poppet (2)
diameter (d1), raising the set pressure to
higher level.
PC400, 450-7E0
67
SEN03589-00

[Installed to port (B) on the boom cylinder head side and port (B) of the service valve]
1.
2.
3.
4.
Spring
Piston
Spring
Holder
Function
q
Enables to provide the safety valve set pressure in two stages, and make the low-pressure
setting smaller.
q
Enables to relieve a load without lever operation if high load is applied to the cylinder.
q
Improves work efficiency and reduces machine
body vibration.
Operation
q
The safety set pressure is determined by
spring (1) installed load.
1.
q
q
q
68
If pilot pressure is OFF (high-pressure setting)

Since pilot pressure (P) is OFF, piston (2) is
pressed to the left by spring (3). [Spring (1)
installed load < spring (3) installed load]
Spring (1) installed load becomes maximum
and the set pressure rises.
Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
PC400, 450-7E0
2.
q
q
q
SEN03589-00
If pilot pressure is ON (low-pressure setting)

If the pilot pressure (P) is ON, the pilot pressure is led to section (A) via passage (B) and
works on the pressure-receiving bore section
(d2 d1).
This pilot pressure contracts spring (3), and
piston (2) moves to the right until making contact with holder (4).
Spring (1) stretches, installed load is reduced,
and the set pressure lowers.
Pressurized oil proportionate to the piston
stroke is drained via passage (C) and chamber
(D).
PC400, 450-7E0
69
SEN03589-00

(Installed to the service valve)
A.
B.
C.
Pump discharge pressure (P) (From service

valve spool)
Cylinder port
Load pressure of other work equipment
1.
2.
3.
4.
5.
6.
7.
8.
Valve
Spring
Sleeve
Poppet
Spring
Screw
Locknut
Cap
70
Function
q
Regulates flow distribution to the service valve
when the service valve (attachment) and the
work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area
ratio variable)
q
Pressurized oil from the service valve spool is
applied to the left side of valve (1) and is led to
chamber (g) via orifice (a).
q
LS pressure is led to chamber (e) through orifice (d).
q
Pressurized oil of cylinder port is led to chamber (h) through passage (c) and orifice (f).
q
The force of spring (2) acts on valve (1), and
the force of spring (5) acts on poppet (4).
q
The force of spring (5) can be adjusted with
screw (6).
PC400, 450-7E0
SEN03589-00
Operation when jointly operated with a high-load work equipment (such as the boom raising)
q
Both of the pump discharge pressure (P) and
q
If the difference between the pump discharge
LS pressures are determined by other equippressure (P) and cylinder port pressure (B) is
ment's pressure, while cylinder port pressure
larger than the force of spring (5), poppet (4) is
causes the attachment to operate.
pressed to the right.
q
If the difference between the pump discharge
q
Pump discharge pressure (P) flows to orifice
pressure (P) and cylinder pressure is smaller
(a) and chamber (g) and is interconnected to
than the force of spring (5), the balance of
cylinder port via passages (b) and (c).
q
Differential pressure is generated between the
forces applying to valve (1) may be expressed
upstream and downstream of orifice (a), which
with the following equation:
reduces the pressure force in chamber (g).
q
Force that presses valve (1) to the left is
P A1 = P A2 + LS(A2 1) + F
reduced.
q
A state is reached where the area ratio has
A1: Area of d1
become smaller.
A2: Area of d2
q
Valve (1) moves to the right, and the flow
F: Force of spring
increases from the pump to the cylinder.
P: Pump discharge oil pressure
PC400, 450-7E0
71
SEN03589-00
Attachment circuit selector valve
ACC:
ATT:
P1:
T:
TS:
V:
To accumulator
To attachment
From attachment selector solenoid valve
To hydraulic oil tank
To hydraulic oil tank
To control valve
1.
2.
Spool
Spring
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
72
Spool return spring
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
132 29
114.5
834 N
{85.0 kg}
667 N
{68.0 kg}
If damaged or
deformed, replace
spring.
PC400, 450-7E0
SEN03589-00
Function
q
When a breaker is installed, the return oil from
the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
q
When other attachments (crusher, etc.) are
installed, the attachment and the main valve
are interconnected.
Operation
1. When attachment other than breaker is
installed
q
Spool (1) is pressed to the left by the force of
spring (2).
q
Ports (ATT) and (V) are interconnected and
ports (ATT) and (T) are shut off. Attachment is
thus interconnected to the control valve.
PC400, 450-7E0
2.
q
q
q
When breaker is installed

Pilot pressure (P1) from the attachment circuit
selector solenoid valve compresses spring (2),
moving spool (1) rightward to the stroke end.
Ports (ATT) and (V) are shut off and ports
(ATT) and (T) are interconnected.
Pressurized oil returning from the breaker
returns directly to the hydraulic tank via port (T)
without passing through the control valve.
73
SEN03589-00
Holding valve
(For the boom and arm)
74
PC400, 450-7E0
CY:
PCY:
PI:
T:
V:
1.
2.
3.
4.
5.
6.
SEN03589-00
To work equipment cylinder

For pressure pickup port and equalizer circuit
From PPC valve
To tank
From control valve
Pilot spool
Spool (1st stage spool)
Spring (2nd stage spool)
Safety valve
Check valve
Spring
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
20.8 12.2
13.5
12.7 N
{1.3 kg}
10.2 N
{1.04 kg}
47.1 N
{4.8 kg}
41.1 9.6
35.0
58.8 N
{6.0 kg}
41.9 25.8
41.0
78.5 N
{8.0 kg}
43.2 25.4
41.0
126 N
{12.8 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
62.8 N
{6.4 kg}
100 N
{10.2 kg}
75
SEN03589-00
Function
q
Prevents the pressurized oil from reversing
from the work equipment cylinder in order to
prevents sudden drift of the work equipment at
breaking of the piping between the control
valve and the work equipment cylinder.
Operation
1. When the work equipment lever is in neutral
When the piping is free of breakage
q
Check valve (5) is closed under the holding
pressure of the cylinder led from port (CY) to
chamber (b).
q
At the neutral, pilot pressure led to port (PI)
from the PPC valve is 0 MPa {0 kg/cm2}.
q
Spool (1) is pressed to the left by the force of
springs (2) and (3)
q
Chambers (a) and (b) are shut off.
q
No pressurized oil flows between the control
valve and the work equipment cylinder.
q
Accordingly, the work equipment is held in
position.
q
If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by
the holding pressure of the work equipment
cylinder.
q
Chambers (b) of L.H. and R.H. holding valve
for the boom are interconnected by port (PCY).
q
Chambers (b) will have the same pressure if
the L.H. and R.H. holding valves have a difference in leakage.
76
If the piping is bursted

q
If piping (A) is broken between the control
valve and the work equipment cylinder, chambers (a) and (b) are shut off in the same way as
the piping is free from damages.
q
Pressure for the work equipment cylinder is
held to prevent a sudden drop of the work
equipment.
PC400, 450-7E0
2.
SEN03589-00
When pressurized oil flows from the main

valve to the cylinder
When the piping is free of breakage

q
Pressurized oil led to chamber (a) from the
control valve becomes higher than the combined force of pressure from work equipment
cylinder circuit chamber (b) and spring (6).
q
Check valve (5) opens and chambers (a) and
(b) are interconnected.
q
Pressurized oil flows from the control valve to
the work equipment cylinder.
If piping (A) between the control valve and the
work equipment cylinder is broken, pressurized oil in chamber (a) flows outside from the
damaged portion.
q
Pressure force in chamber (a) drops.
q
Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b)
and spring (6).
q
Check valve (5) closes and chambers (a) and
(b) are cut off.
q
Pressure for the work equipment cylinder is
held to prevent a sudden drop of the work
equipment.
q
PC400, 450-7E0
77
SEN03589-00
3.
When returning pressurized oil to the main

valve from the work equipment cylinder
When the piping is free of burst

q
Holding pressure of the work equipment cylinder is led to chamber (b) and check valve (5)
closes.
q
Pilot pressure from the PPC valve is led to port
(PI) and reaches [Pilot Pressure > Force of
Spring (3)] (area of d).
q
Spool (1) moves to the right to the standby
position. (1st stage stroke)
q
At this point, chambers (a) and (b) are not
interconnected.
q
Pilot pressure further rises, and reaches [Pilot
pressure > Force of spring (2)] (area of d).
q
Spool (1) moves further to the right, and chambers (a) and (b) are interconnected. (2nd stage
stroke)
q
Pressurized oil returns to the control valve
from the work equipment cylinder.
78

q
If piping (A) bursts between the control valve
and the work equipment cylinder.
q
Pressurized oil in chamber (a) flows out to the
bursted portion but resupplied from chamber
(b).
q
Since pressurized oil flows via opening (c) of
spool (1), a sudden drop of the cylinder is prevented.
PC400, 450-7E0
PC400, 450-7E0
SEN03589-00
79
SEN03589-00

2008 KOMATSU
All Rights Reserved
80
SEN03590-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0


Valve control ................................................................................................................................................... 2
PPC valve ....................................................................................................................................................... 4
Solenoid valve............................................................................................................................................... 20
PPC accumulator .......................................................................................................................................... 22
Return oil filter............................................................................................................................................... 23
Center swivel joint......................................................................................................................................... 24
Travel motor .................................................................................................................................................. 25
Swing motor .................................................................................................................................................. 37
Hydraulic cylinder.......................................................................................................................................... 46
PC400, 450-7E0
SEN03590-00
Valve control
1. Travel PPC valve

2. Service PPC valve
3. Service pedal
4. L.H. travel lever
5. R.H travel lever
6. R.H. PPC valve
7. R.H. work equipment control lever
8. Solenoid valve
9. Accumulator
10. Control valve
11. Hydraulic pump
12. Junction box
13. L.H. work equipment control lever
14. L.H. PPC valve
Lever positions
A. Hold
B.
C.
D.
E.
F.
G.
H.
J.
K.
L.
M.
N.
Boom (RAISE)
Boom (LOWER)
Bucket (DUMP)
Bucket (CURL)
Hold
Arm (IN)
Arm (OUT)
Swing (RIGHT)
Swing (LEFT)
Neutral
Travel (REVERSE)
Travel (FORWARD)
PC400, 450-7E0
PC400, 450-7E0
SEN03590-00
SEN03590-00
PPC valve
Work equipment and swing PPC valve
P:
P1:
P2:
P3:
P4:
T:
From self pressure reducing valve

L.H. PPC: Arm out/R.H. PPC: Boom lower
L.H. PPC: Arm in/R.H. PPC: Boom raise
L.H. PPC: Swing left/R.H. PPC: Bucket curl
L.H. PPC: Swing right/R.H. PPC: Bucket dump
To tank
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (for lever connection)
SEN03590-00
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
42.5 15.5
34.0
17.7 N
{1.80 kg}
13.7 N
{1.40 kg}
13 (for ports P1 and P2)
44.5 15.5
34.0
29.4 N
{3.0 kg}
23.5 N
{2.40 kg}
14 Metering spring
26.5 8.15
24.9
16.7 N
{1.70 kg}
13.7 N
{1.40 kg}
Centering spring
12 (for ports P3 and P4)

Centering spring
PC400, 450-7E0
If damaged or
deformed, replace
spring.
SEN03590-00
Operation
1. When in neutral
q
Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected
to drain chamber (D) via fine control hole (f) in
spool (1).
q
q
q
2.
q
The relationship of the position of spool (1) and

body (10) [fine control hole (f) is in the middle
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) contacts spool (1).
Metering spring (2) contracts in proportion to
the stroke of the control lever.
Pressure at port (P1) also rises in proportion to
In this way, the control valve spool moves to a
position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force
of the return spring of the control valve spool
are balanced.
During fine control

(Neutral o fine control)
When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
PC400, 450-7E0
3.
q
During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port (P1).
Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering
spring (2).
Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the chamber with pressurized oil.
PC400, 450-7E0
SEN03590-00
4.
q
q
At full stroke
Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1).
chamber (D), and is interconnected to pump
pressure chamber (PP).
Therefore, the pilot pressure oil from the self
pressure reducing valve passes through fine
control hole (f) and flows to chamber (A) from
port (P1) to push the control valve spool.
The oil returning from chamber (B) passes
from port (P2) through fine control hole (f') and
flows to drain chamber (D).
SEN03590-00
Travel PPC valve
P:
P1:
P2:
P3:
P4:
P5:
P6:
T:
From main pump

L.H. reverse
L.H. forward
R.H. reverse
R.H. forward
Travel signal
Steering signal
To tank
PC400, 450-7E0
PC400, 450-7E0
SEN03590-00
SEN03590-00
10
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN03590-00
Plate
Body
Piston
Collar
Centering spring
Metering spring
Valve
Dumper
Steering signal spool
Steering signal spool spring
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
48.6 15.5
32.5
108 N
{11.0 kg}
86.3 N
{8.8 kg}
12 Metering spring
26.5 8.15
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
13 Steering signal spring
12.8 7.3
8.5
8.8 N
{0.9 kg}
7.1 N
{0.72 kg}
11 Centering spring
PC400, 450-7E0
If damaged or
deformed, replace
spring.
11
SEN03590-00
1.
Pressure reducing valve
Operation
1) When in neutral
q
Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected
to drain chamber (D) via fine control hole (f) in
spool (1).
q
q
q
2)
q
12
The relationship of the position of spool (1) and

body (10) [fine control hole (f) is in the middle
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) contacts spool (1).
Metering spring (2) contracts in proportion to
Pressure at port (P1) also rises in proportion to
In this way, the control valve spool moves to a
position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force
of the return spring of the control valve spool
are balanced.
During fine control

(Neutral o fine control)
When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
PC400, 450-7E0
3)
q
During fine control

(When control lever is returned)
When lever (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and pressure at port (P1).
Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering
spring (2).
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the chamber with pressurized oil.
SEN03590-00
Therefore, the pilot pressure oil from the self

pressure reducing valve passes through fine
control hole (f) and flows to chamber (A) from
port (P1) to push the control valve spool.
The oil returning from chamber (B) passes
from port (P2) through fine control hole (f') and
flows to drain chamber (D).
2. Travel signal/Steering function

Travel signal
q
Travel signal if either of the L.H. or R.H. travel
levers is operated, the higher PPC output pressure of both sides is output as the travel signal.
q
Accordingly, whether the machine is travelling
is judged by the signal of port (P5).
Steering signal
If the operation quantities of both levers are different from each other as in the steering operat i o n, t h e h i gh e r on e o f t h e P P C o ut pu t
pressures of both sides is output as the steering signal.
q
Any signal is not output from port (P6) while
the machine is travelling straight (forward or
reverse) or in neutral.
q
Accordingly, whether the machine is being
steered is judged by the signal of port (P6).
q
4)
q
q
At full stroke
Lever (5) pushes down piston (4), and retainer
(9) pushes down spool (1).
chamber (D), and is interconnected to pump
pressure chamber (PP).
PC400, 450-7E0
13
SEN03590-00
Operation
1) When in neutral
14
No output is made from respective output ports

[from port (P1) to (P4)], travel signal [port (P5)]
and steering signal [port (P6)].
PC400, 450-7E0
2)
During straight travel
The Illustration shows the circuit for travelling straight forward.
When operating L.H. motor forward [port (P2)

output] and R.H. motor forward [port (P4) output], pressure of both left spring chamber (k)
and right spring chamber (l) rises high.
Steering signal spool (j) remains at neutral
position and does not output a steering signal
to port (P6).
PC400, 450-7E0
SEN03590-00
15
SEN03590-00
3)
When steered or pivot-turned
The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.
If the operation quantities of both levers are different from each other as in the steering operation (if the difference of the pilot pressure
between both sides is higher than a certain
level), the pilot pressure is output as the steering signal.
The pressure in left spring chamber (k) of
steering signal spool (j) is (P2).
The pressure in right spring chamber (l) is
(P4).
When the pressure state reaches [(P4 P2)
(Spool section) > Spring set load], the spool is
switched to the direction of the arrow.
q
q
q
16
Port (P4) pressure of the L.H. or R.H. PPC

valves, whichever having a higher output pressure, is output to port (P6) as the steering signal.
PC400, 450-7E0
4)
When counter-rotated
The illustration shows the circuit for travelling left reverse and right forward.
When operating L.H. motor reverse [port (P1)

output] and R.H. motor forward [port (P4) output], pressure of the right spring chamber (l)
only rises high.
Steering signal spool (j) strokes to the left to
output the steering signal to port (P6).
PC400, 450-7E0
SEN03590-00
17
SEN03590-00
Service PPC valve
18
For the details of operation, see the paragraph of Work equipment swing PPC valve.
PC400, 450-7E0
P:
P1:
P2:
T:
From self pressure reducing valve

To service valve
To service valve
To tank
SEN03590-00
1.
2.
3.
4.
5.
6.
Spool
Piston
Lever
Plate
Retainer
Body
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Centering spring
Metering spring
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
28.4
125 N
{12.7 kg}
100 N
{10.2 kg}
33.9 15.3
22.7 8.10
22.0
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
If damaged or
deformed, replace
spring.
19
SEN03590-00
Solenoid valve
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up and travel junction solenoid valves
1.
2.
3.
4.
5.
6.
7.
20
PPC lock solenoid valve

Travel junction solenoid valve
Merge-divider solenoid valve
Travel speed solenoid valve
Swing brake solenoid valve
Machine push-up solenoid valve
2-stage relief solenoid valve
T:
To tank
A1: To PPC valve
A2: To main valve (Travel junction valve)
A3: To main valve (Merge-divider valve)
A4: To both travel motors
A5: To swing motor
A6: To 2-stage safety valve at boom cylinder head
A8: To main valve (2-stage relief valve)
P1: From main pump
ACC: To accumulator
PC400, 450-7E0
1.
2.
3.
Connector
Moving core
Coil
Operation
When solenoid is de-energized
q
Since the signal current does not flow from the
controller, solenoid (3) is de-energized. For this
reason, spool (4) is pushed to the left by spring
(6). By this operation, the pass from port (P) to
port (A) is closed and the pressurized oil from
the main pump does not flow into the actuator.
At this time, the oil from the actuator is drained
through ports (A) and (T) into the tank.
PC400, 450-7E0
SEN03590-00
4.
5.
6.
Spool
Block
Spring
When solenoid is energized

q
The signal current flows from the controller to
solenoid (3), and the latter is energized.
Accordingly, spool (4) is pressed against to the
right side. By this operation, the pressurized oil
from the main pump flows through port (P) and
spool (4) to port (A), then flows into the actuator. At the same time, port (T) closes and stops
the oil from flowing to the tank.
21
SEN03590-00
PPC accumulator
1
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications
Gas capacity: 300 cc (for PPC)
22
PC400, 450-7E0
Return oil filter
SEN03590-00
For breaker
1.
2.
3.
4.
5.
Drain plug
Filter
Case
Head cover
Relief valve
Specifications
Rated pressure: 6.9 MPa {70 kg/cm2}
Flow: 200 l/min
Relief valve cracking pressure:
0.34 0.05 MPa {3.5 0.5 kg/cm2}
Filter mesh size: 6 m
Filtering area: 4,570 cm2
PC400, 450-7E0
23
SEN03590-00
Center swivel joint
1.
2.
3.
4.
5.
Cover
Body
Slipper seal
O-ring
Shaft
A1:
A2:
B1:
B2:
C1:
C2:
D1:
D2:
E:
T1:
T2:
To L.H. travel motor port PB

From control valve port A2
To L.H. travel motor port PA
From control valve port B2
To R.H. travel motor port PA
From control valve port A5
To R.H. travel motor port PB
From control valve port B5
To L.H. and R.H. travel motors port P
From L.H. and R.H. travel motors port T
To tank
Unit: mm
No.
Check item
Clearance between rotor and
6 shaft
24
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
80
Replace
PC400, 450-7E0
Travel motor
SEN03590-00
Type: KMV200ADT-2
PA:
PB:
PI:
T:
From control valve

From control valve
From travel speed solenoid valve
To tank
PC400, 450-7E0
Specifications
Type
: KMV200ADT-2
Theoretical displacement
(Min.)
: 130 cm3/rev
(Max.)
: 200 cm3/rev
Rated pressure
: 37.3 MPa {380 kg/cm2}
Rated speed
(Capacity min.)
: 2,650 rpm
(Capacity max.)
: 1,550 rpm
Brake release pressure
: 0.98 MPa {10 kg/cm2}
Travel speed selector pressure
(differential pressure) : 0.78 MPa {8 kg/cm2}
25
SEN03590-00
26
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
SEN03590-00
Output shaft
Motor case
Piston
Cylinder block
Valve plate
End cover
Slow return valve
Regulator piston
Plate
Disk
Check valve spring
Check valve
Counter balance valve spool
Spool return spring
Safety valve
Regulator valve
Spring
Brake spring
Brake piston
Check valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
Outside diameter
Installed
length
Installed
load
Free length
Installed
load
62.5 32.0
42.0
427 N
{43.5 kg}
341 N
{34.8 kg}
62.5 20.0
39.0
3.04 N
{0.31 kg}
2.45 N
{0.25 kg}
23 Regulator piston spring
55.0 9.0
50.0
98.1 N
{10.0 kg}
78.5 N
{8.0 kg}
PC400, 450-7E0
If damaged or
deformed, replace
spring.
27
SEN03590-00
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q
q
q
q
28
As the solenoid valve is de-energized, the pilot

pressurized oil from the self pressure reducing
valve does not flow to port (P).
Regulator valve (16) is being pushed down by
spring (17).
Pressurized oil conducted to end cover (6) by
pressing check valve (20) is then conducted to
chamber (b) via regulator valve (16).
Force is generated on regulator piston (8) that
works in downward direction.
Valve plate (5) and cylinder block (4) move in
the maximum tilt and roll angle direction,
increasing the motor capacity to the maximum
and thus turning on the low speed travel.
PC400, 450-7E0
2)
At high speed (motor swash plate angle at minimum)
As the solenoid valve is energized, the pilot

pressurized oil from the self pressure reducing
valve flows to port (P).
Regulator valve (16) is pushed upward.
Pressurized oil in chamber (b) is drained to the
case and oil is conducted to chamber (a)
through regulator valve (16).
Force is generated on regulator piston (8) that
works in upward direction.
Valve plate (5) and cylinder block (4) move in
the minimum tilt and rotation angle direction,
decreasing the motor capacity to the minimum
and thus turning on the high speed travel.
q
q
q
q
PC400, 450-7E0
SEN03590-00
29
SEN03590-00
Operation of parking brake

1) When starting travel
30
As the travel lever is operated, pressurized oil

from the pump activates counterbalance valve
spool (13), opening the parking brake circuit.
The pressurized oil is conducted to chamber
(e) of brake piston (19) and compresses spring
(18), pushing piston (19) toward right.
Since the pushing force to plate (9) and disc
(10) disappears, plate (9) is separated from
disc (10) and the brake is released.
PC400, 450-7E0
2)
When travel is stopped
As the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral
position and closing the parking brake circuit.
Pressurized oil in chamber (e) of brake piston
(19) keeps flowing through the orifice of slow
return valve (7) until counter balance valve
spool (13) is returned to the neutral.
As counter balance valve spool (13) is
returned to the neutral, pressurized oil is
drained to the case through orifice (f) of brake
piston (19).
Brake piston (19) is pushed to the left by spring
(18).
Plate (9) and disc (10) are pushed together,
and the brake is applied.
q
q
PC400, 450-7E0
SEN03590-00
q
q
As brake piston (19) returns, flow of pressurized oil is reduced with slow return valve (7).
The time delay will be set to activate the brake
only after the machine has stopped.
31
SEN03590-00
Brake valve
q
The brake valve consists of check valves (1),
counterbalance valve (2) and safety valve (3).
q
Functions and operations of respective components shall conform to the following.
1.
Counterbalance valve and check valve
Function
When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q
If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away, resulting in a
very dangerous situation.
q
These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).
Operation when pressurized oil is supplied

q
Operating the travel lever conducts the pressurized oil from the control valve to port (PA).
q
The pressurized oil push-opens check valve
(12A) and then flows to motor outlet port (MB)
via motor inlet port (MA).
q
The motor outlet side is closed by check valve
(12B) and spool (13), so the pressure at the
supply side rises.
32
PC400, 450-7E0
The pressurized oil on the supply side flows to

chamber (S1) via orifice (E1) and orifice (E2) of
the spool (13).
As the pressure in chamber (S1) goes above
the spool selector pressure, spool (13) is
pushed toward right.
Port (MB) and port (PB) are connected, opening the motor outlet port side and starting the
motor rotating.
PC400, 450-7E0
SEN03590-00
Operation of brake during travelling downhill

q
If indication of the machine runaway is sensed
while travelling downhill, the motor will be
caused to rotate without load to decrease the
inlet side oil pressure.
q
Pressure in chamber (S1) is released through
orifices (E1) and (E2).
q
As the pressure in chamber (S1) goes below
the spool selector pressure, spool (13) is
returned to the left by spring (14) and outlet
port (MB) is throttled.
q
The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from running away.
q
The spool moves to a position where the pressure on outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q
Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.
33
SEN03590-00
2.
Safety valve
(bidirectional 2-stage set safety valve)
Function
q
As long as the machine travel is stopped (or it
is travelling downhill), the counterbalance
valve closes the inlet and outlet circuits of the
motor.
q
Since the motor is rotated by inertial force,
pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping.
q
The safety valve releases this abnormal pressure to the inlet port side of the motor in order
to prevent damages to the equipment.
As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D2)
Pressure] compresses spring (2).
Poppet (1) is moved leftward and the pressurized oil flows into chamber (MA) of the opposite circuit.
Bidirectional action
1) When pressure in chamber (MB) has
become high (when rotating clockwise)
q
is travelling downhill), the check valve of counterbalance valve closes chamber (MB) of the
outlet port circuit.
q
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
34
PC400, 450-7E0
2)
When pressure in chamber (MA) has

become high (when rotating counterclockwise)
is travelling downhill), the check valve of counterbalance valve closes chamber (MA) of the
outlet port circuit.
The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MA) is increased.
SEN03590-00
Operation of mechanism for varying set pressure

1) When starting travel (high-pressure setting)
q
As the travel lever is operated, the pressurized
oil from the pump moves spool (19) toward
right.
q
Above opens the pilot circuit to the safety
valve, conducting the pressurized oil to chamber (J) through chamber (G) and passage (H).
q
Piston (3) is pushed rightward, spring (2) is
compressed and the set load is increased.
q
High pressure is turned on the safety valve,
providing a large tractional force to the valve.
As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D3)
Pressure] compresses spring (2).
Poppet (1) is moved leftward and the pressurized oil flows into chamber (MB) of the opposite circuit.
PC400, 450-7E0
35
SEN03590-00
2)
q
q
q
When travel is stopped (low-pressure setting)

When the travel lever is placed in neutral, the
pressure in chamber (PA) drops and spool (24)
returns to the neutral position.
When spool (24) is in the process of returning
to the neutral position, the pressurized oil in
chamber (J) flows to chamber (PA) through
passage (H) and chamber (G).
Piston (3) moves to the left side, decreasing
the set load.
The safety valve is caused to the low pressure
setting, thereby attenuating the shocks when
the speed is reduced.
Set pressure of safety valve

High pressure setting: 40.2 MPa {410 kg/cm2}
(at start of travel and during travel)
Low pressure setting: 27.5 MPa {280 kg/cm2}
(during stop)
36
PC400, 450-7E0
Swing motor
SEN03590-00
Type: KMF230ABE-5
B: From swing holding brake solenoid valve

MA: From control valve
MB: From control valve
S: From control valve
T: To tank
1.
2.
Reverse prevention valve

Safety valve
PC400, 450-7E0
Specifications
Type
Theoretical displacement
Safety valve set pressure
Rated speed
Brake release pressure
: KMF230ABE-5
: 229.4 cm3/rev
: 27.9 MPa {285 kg/cm2}
: 1,413 rpm
: 1.9 MPa {19 kg/cm2}
37
SEN03590-00
38
PC400, 450-7E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
SEN03590-00
Brake spring
Drive shaft
Spacer
Case
Disc
Plate
Brake piston
Housing
Piston
Cylinder block
Valve plate
Center shaft
Center spring
Check valve
Check valve spring
Shuttle valve
Shuttle valve spring
Unit: mm
No.
Check item
Criteria
Remedy
Basic dimensions
19 Shuttle valve spring
PC400, 450-7E0
Free length
Outside diameter
Repair limit
Installed
length
Installed
load
Free length
Installed
load
45.0
6.96 N
{0.71 kg}
5.59 N
{0.57 kg}
66.5 25.6
24.5 11.6
14.5
7.45 N
{0.76 kg}
5.98 N
{0.61 kg}
If damaged or
deformed, replace
spring.
39
SEN03590-00
Swing holding brake

1. When solenoid valve is de-energized
Operation
q
As the swing holding brake is de-energized,
the pressurized oil from the self pressure
reducing valve is shut off.
q
Port (B) is connected to tank circuit (T).
q
Brake piston (7) is pushed down by brake
spring (1).
q
Disc (5) and plate (6) are pushed together, and
the brake is applied.
40
2.
When solenoid valve is energized
Operation
q
As the swing brake solenoid valve is energized, the valve is switched.
q
The pressurized oil from the self pressure
reducing valve is conducted brake chamber (a)
via port (B).
q
After entering chamber (a), the pressurized oil
compresses brake spring (1) and pushes
brake piston (7) up.
q
Disc (5) is separated from plate (6), releasing
the brake.
PC400, 450-7E0
Relief valve portion
SEN03590-00
2.
q
Outline
q
The relief valve portion consists of check
valves (2) and (3), shuttle valves (4) and (5),
and relief valve (1).
Function
When the machine is in the swing holding
mode, control valve (6) closes the motor outlet
circuit, but the motor rotation is continued by
inertial force.
q
The motor output, therefore, is abnormally
increased, resulting in damaging the motor.
q
In order to prevent the motor damages, the
relief valve relieves the abnormally high pressure to port (S) from the motor outlet side
(high-pressure side) of the motor.
q
Operation
1. When starting swing
q
When the swing control lever is operated to the
right- swing, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
q
The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q
The pressurized oil from the outlet port of the
motor passes from port (MB) through the control valve (6) and returns to the tank.
PC400, 450-7E0
q
q
q
q
q
When swing is stopped

When the swing control lever is returned to
neutral, the supply of pressurized oil from the
pump to port (MA) is stopped.
The pressurized oil from the motor outlet can't
return to the tank since the returning circuit to
the tank is closed from control valve (6). Thus,
pressure on port (MB) increases.
Rotation resistance is generated on the motor
and hence the brake starts working.
Shuttle valve (4) is pressed as pressure on
port (MB) goes above port (MA).
The pressure on chamber (C) is increased to
the set pres sure of relief valve (1) and
becomes the same as that of port (MB).
A high braking torque works on the motor,
thereby stopping the motor.
When relief valve (1) is being actuated, the
relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) through
check valve (3).
Above prevents cavitation on port (MA).
41
SEN03590-00
Reverse prevention valve
42
PC400, 450-7E0
SEN03590-00
MA: From control valve

MB: From control valve
T1: To tank
T2: To tank
1.
2.
3.
4.
5.
6.
7.
Valve body
Spool (MA side)
Spring (MA side)
Plug (MA side)
Spool (MB side)
Spring (MB side)
Plug (MB side)
Explanatory drawing of effects
PC400, 450-7E0
43
SEN03590-00
Function
q
This valve reduces the swing back generation
in the swing body by the inertia of the swing
body, the backlash and rigidity of the machinery system, and the compression of the
hydraulic oil when the swing is stopped.
q
The valve contributes in preventing collapsing
of load when the swing is stopped and also
contributes in reducing cycle time (enhances
the positioning performance, enabling you to
proceed to the next work quicker than ever).
2.
q
q
q
q
q
Operation
1. When port (MB) brake pressure is generated
q
Pressure (MB) is conducted to chamber (d) via
notch (g).
q
The pressure compresses spring (6) by use of
the difference in areas of circles (D1 > D2) of
spool (5) and moves spool (5) to the left side.
q
Port (MB) o chamber (e) will be interconnected.
q
Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.
44
When motor is stopped temporarily

The motor rotation is reversed by the closing
pressure generated at port (MB). (1st time:
reverse rotation)
Reversing pressure is generated on port (MA).
Pressure (MA) is conducted to chamber (a).
The pressure compresses spring (3) by use of
the difference in areas of circles (D3 > D4) of
spool (2) and moves spool (2) to the right side.
Port (MA) o chamber (b) will be interconnected.
Then ports (b) and (f) will be interconnected
through the drilled hole (h) on spool (5). This
interconnection bypasses the reversing pressure on port (MA) to port (T), thereby preventing the reverse rotation of the 2nd time.
PC400, 450-7E0
PC400, 450-7E0
SEN03590-00
45
SEN03590-00
Hydraulic cylinder
Boom cylinder
Arm cylinder
Bucket cylinder
46
PC400, 450-7E0
SEN03590-00
Unit: mm
No.
Check item
Hole
Standard
clearance
Clearance
limit
110
0.036
0.090
+0.261
+0.047
0.083
0.351
0.412
Arm
120
0.036
0.090
+0.263
+0.048
0.084
0.353
0.412
Bucket
110
0.036
0.090
+0.257
+0.047
0.083
0.347
0.447
Boom
110
0.036
0.090
+0.169
+0.100
0.136
0.259
Clearance between
piston rod support pin
and bushing
Arm
110
0.036
0.090
+0.169
+0.100
0.136
0.259
Bucket
100
0.036
0.090
+0.187
+0.097
0.133
0.277
100
0.036
0.090
+0.190
+0.070
0.106
0.280
110
0.036
0.090
+0.195
+0.099
0.135
0.285
100
0.036
0.090
+0.187
+0.097
0.133
0.277
Boom
Boom
Standard
size
Clearance between
3 cylinder bottom support Arm

pin and bushing
Bucket
PC400, 450-7E0
Remedy
Shaft
Cylinder
Clearance between
piston rod and bushing
Criteria
Tolerance
Replace bushing
Replace pin or
bushing
47
SEN03590-00

Boom cylinder
Arm cylinder
Bucket cylinder
48
PC400, 450-7E0
SEN03590-00
Bottom dump cylinder
Unit: mm
No.
Check item
Hole
Standard
clearance
Clearance
limit
100
0.036
0.090
+0.261
+0.047
0.083
0.351
0.415
120
0.036
0.090
+0.263
+0.048
0.084
0.353
0.453
Bucket
95
0.036
0.090
+0.222
+0.047
0.083
0.312
0.412
Bottom dump
90
0.036
0.090
+0.257
+0.048
0.084
0.347
0.447
Boom
110
0.036
0.090
+0.457
+0.370
0.136
0.259
1.0
Arm
110
0.036
0.090
+0.457
+0.370
0.406
0.547
1.0
Bucket
100
0.036
0.090
+0.457
+0.370
0.406
0.547
1.0
Bottom dump
80
0.036
0.090
+0.457
+0.370
0.406
0.547
1.0
100
0.036
0.090
+0.161
+0.074
0.110
0.251
1.0
110
0.036
0.090
+0.457
+0.370
0.496
0.547
1.0
80
0.036
0.090
+0.457
+0.370
0.496
0.547
1.0
80
0.036
0.090
+0.457
+0.370
0.406
0.547
1.0
Boom
Clearance between
1 piston rod and bushing Arm
Boom
Arm
Clearance between
cylinder bottom support
pin and bushing
Bucket
Bottom dump
PC400, 450-7E0
Standard
size
Remedy
Shaft
Cylinder
Clearance between
piston rod support pin
and bushing
Criteria
Tolerance
Replace bushing
Replace pin or
bushing
49
SEN03590-00

2008 KOMATSU
All Rights Reserved
50
SEN03591-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 6
PC400, 450-7E0
SEN03591-00
Work equipment
PC400, 450-7E0
SEN03591-00
Unit: mm
No.
Check item
Clearance between connecting pin

and bushing of revolving frame
and boom
2 and bushing of boom and arm
3 and bushing of arm and link
4 and bushing of arm and bucket
5 and bushing of link and bucket
6 and bushing of link and link

7 Bucket clearance (a)
8 Bucket clearance (b)
PC400, 450-7E0
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.173
+0.101
0.137 0.263
1.0
0.036
0.090
+0.180
+0.112
0.148 0.270
1.0
100
0.036
0.090
+0.172
+0.081
0.117 0.262
1.0
100
0.036
0.090
+0.138
+0.077
0.113 0.228
1.0
100
0.036
0.090
+0.172
+0.081
0.117 0.262
1.0
100
0.036
0.090
+0.190
+0.097
0.133 0.280
1.0
Shaft
Hole
120
0.036
0.090
120
0.5 1.0
2.0
Replace
Adjust shims
SEN03591-00
PC400, 450-7E0
SEN03591-00
Unit: mm
No.
Check item

and bushing of revolving frame
and boom
2 and bushing of boom and arm
3 and bushing of arm and bucket
Criteria
Standard
size
Standard
clearance
Clearance
limit
+0.351
+0.270
0.306 0.344
1.0
0.036
0.090
+0.380
+0.283
0.306 0.470
1.0
100
0.036
0.090
+0.352
+0.283
0.319 0.442
1.0
100
0.036
0.090
+0.338
+0.284
0.320 0.428
1.0
95
0.036
0.090
+0.344
+0.272
0.308 0.434
1.0
Shaft
Hole
120
0.036
0.090
120
4 and bushing of bucket cylinder

and bucket
5 and bushing of front bucket and

rear bucket
PC400, 450-7E0
Tolerance
Remedy
Replace
SEN03591-00
Dimensions of components
1.
Dimension of arm
PC400, 450-7E0
SEN03591-00
Unit: mm
PC400-7E0
No.
Measuring position
1
2
Standard
size
110
PC450-7E0
Tolerance
Shaft
Hole
0.036
0.090
+0.1
0
Standard
size
110
Tolerance
Shaft
Hole
0.036
0.090
+0.1
0
+1.5
0
129.3
126
1.2
126
1.2
Boom side
355
+0.5
0
355
+0.5
0
Arm side
351
0.3
0.8
351
0.3
0.8
Arm side
129.3
Cylinder head side
3
0.036
0.090
+1.0
0
0.036
0.090
+0.1
0
120
514.8
570.6
195
208.2
1,038
1,132.2
3,375
3,375
2,977.5
2,975.1
10
502
506.8
11
720
720
12
719
719
13
537.1
537.1
14
1,850
1,817
15
100
0.036
0.090
0.036
0.090
+0.1
0
371
+1
0
371
+1
0
Link side
370
0.5
370
0.5
17
Arm itself
When press fitting bushing
19
100
Bucket side
16
18
+0.1
0
120
+1.5
0
100
355
0.036
0.090
+0.1
0
0
0.5
100
355
0.036
0.090
+0.1
0
0
0.5
370
370
Min.
1,870
1,870
Max.
3,140
3,140
PC400, 450-7E0
SEN03591-00
2.
Dimension of bucket
PC400, 450-7E0
SEN03591-00
Unit: mm
No.
Measuring position
1
2
3
4
5
6
7
8
PC450-7E0
Standard size
Tolerance
Standard size
Tolerance
534.1
0.5
534.1
0.5
56.3
0.5
56.3
0.5
961'
9414'
537.1
537.1
1,839
1,806
190
198
621'
461'
140.1
+0.1
0
140.1
+0.1
0
130
+0.063
+0.054
130
+0.063
+0.054
100
+0.1
0
100
+0.1
0
371
+1
+0
371
+1
+0
57
58
10
A
B
11
PC400-7E0
72
72
12
144
144
13
562.5
+0.5
2.5
562.5
+0.5
2.5
14
26
26
165
165
A
B
15
16
17
18
19
20
21
22
PC400, 450-7E0
230
230
146.1
135.5
137.6
142
R115
R115
R85
R85
410
410
64
64
SEN03591-00

2008 KOMATSU
All Rights Reserved
10
SEN03592-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0


Air conditioner piping ...................................................................................................................................... 2
PC400, 450-7E0
SEN03592-00
Air conditioner piping
1.
2.
3.
4.
5.
6.
7.
8.
Receiver tank
Condenser
Air conditioner compressor
Refrigerant piping
Hot water pickup piping
Hot water return piping
Air conditioner unit
Duct
A: Fresh air
B: Recirculated air
C: Hot/cool air
PC400, 450-7E0
PC400, 450-7E0
SEN03592-00
SEN03592-00

2008 KOMATSU
All Rights Reserved
SEN03593-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Electrical system
Engine control ................................................................................................................................................. 2
Electronic control system ...............................................................................................................................11
Monitor system.............................................................................................................................................. 36
Sensor........................................................................................................................................................... 54
KOMTRAX terminal system .......................................................................................................................... 57
PC400, 450-7E0
SEN03593-00
Engine control
Operation of system
Starting engine
q
When the starting switch is turned to the
START position, the starting signal flows to
the starting motor. Then, the starting motor
turns to start the engine.
Stopping engine
q
When detecting that the starting switch is set to
the STOP position, the engine controller cuts
the fuel injection to stop the engine.
When it happens, the engine controller checks

the signal voltage from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

q
The fuel control dial sends a signal voltage corresponding to the rotation angle to the engine
controller.
q
The pump controller receives the fuel dial position information from the engine controller
through the network.
q
The pump controller calculates the engine
speed in accordance with the working mode,
the deceleration, and the like, and sends an
instruction to the engine controller.
q
The engine controller determines the fuel injection quantity based on the instruction received
from the pump controller.
PC400, 450-7E0
SEN03593-00
Component
Fuel control dial
1.
2.
3.
Knob
Dial
Spring
4.
5.
6.
Ball
Potentiometer
Connector
Function
q
A potentiometer is installed under the knob. As
the knob is turned, the potentiometer shaft is
turned.
q
As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer
(5) changes and a throttle signal is sent to the
engine controller.
q
The hatched area in the graph shown at right is
the abnormality detection area.
PC400, 450-7E0
SEN03593-00
Engine controller
Meanings of signal classes in the terminal

table shown below are as follows.
A: Power Supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
CN-CE01
Input/
output
1
NC(*)
2
NC(*)
3
Atmosphere sensor
D
4
Supply pump #1 (+)
B
5
Supply pump #1 ()
C
6
CAN(+)
C
7
NC(*)
8
CAN(+)
B
9
Supply pump #2 (+)
B
10
Supply pump #2 ()
C
*: Never connect to NC or malfunctions or failures will
occur.
Pin No.
Signal name
CN-CE01
Input/
output
11
EGR valve
C
12
NC(*)
13
Engine oil pressure sensor
D
14
NC(*)
15
Coolant temperature sensor
D
16
5V electric power supply for sensor
A
17
NC(*)
18
NC(*)
19
EGR valve position sensor
D
20
NC(*)
21
NC(*)
22
EGR valve (+)
B
23
Boost temperature sensor
D
24
NC(*)
25
Common rail pressure sensor
D
26
Buckup sensor
D
27
NE sensor (+)
D
occur.
Pin No.
Signal name
PC400, 450-7E0
CN-CE01
CN-CE02
Input/
output
28
NC(*)
29
NC(*)
30
Fuel temperature sensor
D
31
NC(*)
32
NC(*)
33
5 V electric power supply for sensor
A
34
NC(*)
35
NC(*)
36
NC(*)
37
5 V electric power supply for sensor
A
38
GND
C
39
NC(*)
40
NC(*)
41
NC(*)
42
NC(*)
43
NC(*)
44
Boost pressure sensor
D
45
Injector #1 (+)
B
46
Injector #5 (+)
B
47
Sensor GND
C
48
Ne sensor ()
C
49
NC(*)
50
NC(*)
51
Injector #2 ()
C
52
Injector #3 ()
C
53
Injector #1 ()
C
54
Injector #2 (+)
B
55
Injector #3 (+)
B
56
Injector #4 (+)
B
57
Injector #6 (+)
B
58
Injector #4 ()
C
59
Injector #6 ()
C
60
Injector #5 ()
C
occur.
Pin No.
Signal name
CN-CE02
Input/
output
1
NC(*)
B
2
NC(*)
B
3
NC(*)
B
4
NC(*)
B
5
NC(*)
B
6
NC(*)
B
7
NC(*)
B
8
NC(*)
B
9
Fuel control dial (+)
B
10
NC(*)
E
11
NC(*)
B
12
NC(*)
B
occur.
Pin No.
PC400, 450-7E0
SEN03593-00
Signal name
Pin No.
Signal name
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Input/
output
B
B
B
B
B
B
B
E
A
A
C
B
B
B
B
B
C
B
B
C
C
C
B
B
C
D
B
D
D
C
D
D
E
E
D
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
Fuel control dial (+5V)
Fuel control dial ()
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
GND
NC(*)
NC(*)
NC(*)
NC(*)
NC(*)
Key switch (ACC)
Electrical intake air heater relay drive
NC(*)
Electrical intake air heater relay return
NC(*)
NC(*)
NC(*)
CAN(+)
CAN()
NC(*)
PWM OUTPUT
49
D
(Power train relay output)
50
NC(*)
D
occur.
CN-CE03
Pin No.
1
2
Signal name
Input/
output
C
C
GND
NC(*)
Electric power supply
3
A
(+24V constantly)
4
NC(*)
A
occur.
SEN03593-00
Rotation sensor
1.
2.
3.
Connector
Sensor
O-ring
Oil pressure switch
1.
2.
3.
Connector
Sensor
O-ring
PC400, 450-7E0
SEN03593-00
Ambient pressure sensor
1.
2.
Connector
Pressure import port
1.
2.
3.
O-ring
Sensor
Connector
PC400, 450-7E0
SEN03593-00
1.
2.
3.
Connector
Sensor
O-ring
Coolant temperature sensor, hydraulic oil temperature sensor
1.
2.
3.
Connector
Sensor
O-ring
PC400, 450-7E0
SEN03593-00
EGR valve stroke sensor
1.
2.
3.
4.
Core
O-ring
Sensor
Connector
PC400, 450-7E0
SEN03593-00
Engine oil level sensor
1.
2.
3.
4.
10
Connector
Bracket
Float
Switch
PC400, 450-7E0
Electronic control system
SEN03593-00
Control function
1
Engine and pump composite control function
2
Pump and valve control function
3
Power maximizing function
Machine push-up function
4
Auto-deceleration function
5
Auto-warm-up and overheat prevention function
Electronic control system
6
Swing control function
7
Travel control function
8
Attachment flow control and circuit selector function
(if equipped)
Self-diagnosis function
a
For the self-diagnosis function, see Troubleshooting.
PC400, 450-7E0
11
SEN03593-00
Machine control system diagram
12
PC400, 450-7E0
PC400, 450-7E0
SEN03593-00
13
SEN03593-00
1.
14
Engine and pump composite control function
PC400, 450-7E0
Function
q
This function allows the operator to select
proper engine torque and pump absorption
torque according to the type of work. Four
modes are provided: P, E, B and L. Using the
work mode switch on the monitor panel, the
operator is required to select one of them.
q
The pump controller detects the speed of the
engine governor set with the fuel control dial
and the actual engine speed (N) and controls
them so that the pump will absorb all the
torque at each output point of the engine,
according to the pump absorption torque set in
each mode.
PC400, 450-7E0
SEN03593-00
1)
Control method in each mode

P and E modes
q
Matching point in P mode: Rated speed
Mode
Matching point
246.3 kW/1,850 rpm

{330 HP/1,850 rpm}
213.3 kW/1,720 rpm

{286 HP/1,720 rpm}
If the pump load increases and the pressure rises, engine speed (N) lowers. At
this time, the controller lowers the pump
discharge so that the engine speed will be
near the maximum output point.
If the pressure lowers, the controller
increases pump discharge (Q) so that the
engine speed will be near the maximum
output point.
By repeating these operations, the controller constantly uses the engine near the
maximum output point.
15
SEN03593-00
B and L modes
Mode
Partial output point
Mode
B
L
q
16
B mode
82%
L mode
61%
Matching point
194.9 kW/1,730 rpm
{261 HP/1,730 rpm}
150.8 kW/1,250 rpm
{202 HP/1,250 rpm}
In B or L mode, the controller controls the

pump absorption torque through the pump
and engine compound control function to
decrease engine speed (N) while maintaining engine torque (T) constant along
the constant horsepower curve. This
ensures reduced fuel consumption.
PC400, 450-7E0
2)
Function to control pump during travel

q
Traveling the machine in E or B mode
leaves the working mode unchanged, but
raises the pump absorption torque and
engine speed (N) to values same as those
in P mode.
q
If the machine travels in L mode, the working mode and engine speed (N) do not
change, but the pump absorption torque is
increased.
PC400, 450-7E0
SEN03593-00
3)
q
Function to control when emergency pump

drive switch is turned on
Even if any abnormality occurs in the controller
or sensor, setting emergency pump drive
switch (10) to the ON position activates the
machine with an absorption torque approximately equivalent to that in E mode.
In this case, a constant current flows from the
battery to the EPC valve for PC and therefore,
the oil pressure is sensed by only the EPC
valve for PC.
17
SEN03593-00
2.
Pump and valve control function
Function
q
The machine is matched to various types of
work properly with the 2-stage relief function to
increase the digging force, etc.
18
PC400, 450-7E0
1)
2)
LS control function
q
Depending on the operation condition of
the actuator, this function changes the
pressure output from the LS-EPC valve to
LS valve to change the change point (LS
set differential pressure (DLS)) of the
pump discharge in the LS valve.
q
By this operation, the start-up time of the
pump discharge is optimized and the composite operation and fine control performance is improved.
SEN03593-00
3)
2-stage relief function

q
The relief pressure in the normal work is
34.8 MPa {355 kg/cm 2 }. If the 2-stage
relief function is turned on, however, the
relief pressure rises to about 37.2 MPa
{380 kg/cm 2 }. By this operation, the
hydraulic force is increased further.
Operating condition for turning on

During travel
When swing lock switch is turned to
the ON position
When boom is lowered
When power maximizing function is
turned on
When L mode is operated
Relief pressure
34.8 MPa
{355 kg/cm2}
O
37.2 MPa
{380 kg/cm2}
Cut-off function
This function increases PC-EPC current
(J) to reduce the flow rate in the relief
state, improving fuel consumption.
Operating condition for turning on cut-off function

When the average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} with the power
maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in
the ON position.
PC400, 450-7E0
19
SEN03593-00
3.
Power maximizing and machine push-up function
Function
q
The power maximizing function allows the
operator to increase power for a certain time
by operating the left knob switch.
q
The machine push-up function allows the operator to increase the boom pushing force by
operating the machine push-up switch.
20
PC400, 450-7E0
1)
Power maximizing function

q
This function is used to increase digging
force for a certain period of time (e.g.,
when digging up a large rock).
q
If the left knob switch is pressed in P or E
mode, the hydraulic force is increased
about 7% to increase the digging force.
Each function is set automatically as
shown below.
Function
Engine and pump
control
Software cut-off function

q
Setting
Matching at rated ouptut
point
34.8 MPa
{355 kg/cm2}
O
37.2 MPa
{380 kg/cm2}
Cancel
SEN03593-00
2)
Machine push-up function

q
The machine push-up function allows the
operator to increase the boom pushing
force that is required for ditching or mass
excavation in hard ground by operating
machine push-up switch (1).
Switch
OFF
ON
2-stage safety valve

function
Setting of safety valve at
boom cylinder head
14.7 MPa
{150 kg/cm2}
Setting of safety valve at
boom cylinder head
28.4 MPa
{290 kg/cm2}
These settings are automatically reset after

8.5 seconds when the switch is pressed.
PC400, 450-7E0
21
SEN03593-00
4.
Auto-deceleration function
Function
q
The auto-deceleration function automatically
reduces the engine speed to its medium speed
range when the all control levers are set in
NEUTRAL while waiting for a dump truck or
work to reduce the fuel consumption and
noise.
q
If any lever is operated, the engine speed
instantly returns to the speed set with the fuel
control dial.
Operation
When control levers are set in neutral
q
If all the control levers are kept to NEUTRAL
for 4 sec. during operation at a engine speed
above a decelerator operation level (approximately 1,300 rpm), this function lowers the
engine speed to the deceleration operation
level (approximately 1,300 rpm) and keeps it
until you operate any lever.
When any control lever is operated
q
If you operate any control lever while the
engine speed is kept at the deceleration operation level, the engine speed instantly rises to
the level set with the fuel control dial.
22
PC400, 450-7E0
5.
SEN03593-00
Auto-warm-up and overheat prevention function
Function
q
The engine automatic warm-up function
increases the engine speed to warm up the
engine if coolant temperature is too low after
the engine starts.
q
The overheat prevention function reduces the
pump load when coolant or hydraulic oil temperature is too high during operation to protect
the engine from overheating.
PC400, 450-7E0
23
SEN03593-00
1)
Auto-warm-up function
q
After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine.
Operating condition (All)
Coolant temperature: Below 30C.

Engine speed: Max. 1,200 rpm
Operated
Engine speed: Max. 1,200 rpm
Auto
Manual
2)
Resetting condition (Any one)

Coolant temperature: Above 30C
Auto-warm-up operation time: Min. 10 minutes
Fuel control dial: Kept at 70% of full level for 3
sec. or longer
Engine speed: Any level
Overheat prevention function

q
If the engine coolant temperature rises too high during work, the pump load and engine speed are
reduced to protect the engine from overheating.
q
This function is turned on when the coolant temperature rises above 95C.
Operating condition
Hydraulic oil
temperature:
Above 95C
Operation/Remedy
Operating condition
Hydraulic oil or
coolant temperature:
Above 100C
Hydraulic oil or
Above 102C
Work mode: Travel

Engine speed: Keep as is.
Lower travel speed.
Resetting condition
Hydraulic oil temperature:
Below 95C
Under above condition, controller
is set to condition before operation of function. (Automatic reset)
Resetting condition
Hydraulic oil or coolant temperature:
Below 100C
Resetting condition
Below 102C
Resetting condition
Below 105C
Fuel control dial: Return to low idle
position once.
is set to condition before operation of function. (Manual reset)
Operation/Remedy
Work mode: P or E mode

Lower pump discharge.
Operation/Remedy
Work mode: P, E, B or Lmode
Monitor alarm lamp: Lights
up.
Lower pump discharge.
Operating condition
Operating condition
Operation/Remedy
Hydraulic oil or
Above 105C
Work mode: Any mode

Engine speed: Low idle
Monitor alarm lamp: Lights up
Alarm buzzer: Sounds
24
Reset
PC400, 450-7E0
6.
SEN03593-00
Swing control function
Function
The swing lock and swing holding brake function
are provided as a swing control function.
PC400, 450-7E0
25
SEN03593-00
1)
Swing lock and swing holding brake function

q
The swing lock function (manual) is used
to lock machine from swinging at any position. The swing holding brake function
(automatic) is used to prevent hydraulic
drift after the machine stops swinging.
q
Operation of swing lock switch and swing
lock/holding brake
Lock
switch
Lock
lamp
Function
OFF
OFF
Swing
holding
brake
ON
ON
Swing
lock
2)
Quick hydraulic oil warm-up function when

swing lock switch is turned on
q
If swing lock switch (4) is turned on, the
pump cut-off function is cancelled and the
relief pressure rises from 34.8 MPa {355
kg/cm2} to 37.2 MPa {380 kg/cm2}. If the
work equipment is relieved under this condition, the hydraulic oil temperature rises
quickly and the warm-up time can be
shortened.
Operation
If swing lever is set in
neutral, swing brake
operates in about 7 sec.
If swing lever is operated, brake is released
and machine can swing
freely.
Swing lock operates and
machine is locked from
swinging.
Even if swing lever is
operated, swing lock is
not reset and machine
does not swing.
Swing holding brake release switch

If the controller, etc. has a problem, the
swing holding brake does not work normally, and the machine cannot swing, the
swing lock can be reset with the swing
holding brake release switch.
q
Even if the swing holding brake release
switch is turned on, if the swing lock
switch is turned on, the swing brake is not
released.
q
If the swing lock is reset, only the hydraulic brake is applied by the safety valve.
Note that if swinging is stopped on a
slope, the upper structure may swing by
its gravity.
q
Swing
holding
brake
release
switch
Swing lock
switch
Swing
brake
26
ON
(when controller has
trouble)
ON
OFF
OFF
(when controller is normaly)
ON
Swing lock Swing lock Swing lock

is turned
is canis turned
on.
celed.
on.
OFF
Swing
holding
brake is
turned on.
PC400, 450-7E0
7.
SEN03593-00
Travel control function
Function
q
The machine is provided with a function that
ensures travel performance best fit to the type
of work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
PC400, 450-7E0
27
SEN03593-00
1)
28
Pump control function during travel

q
If the machine travels in a work mode
other than P mode, the work mode and
the engine speed are kept as they are and
the pump absorption torque is increased.
q
For details, see "Engine and pump composite control function."
2)
Travel speed change function

1] Manual change with travel speed switch
If one of Lo, Mi and Hi is selected with the
travel speed switch, the pump controller
controls the pump capacity and motor
capacity at each gear speed as shown
below to change the travel speed.
Travel speed
switch
Lo (Low
speed)
Pump capacity (%)

Motor capacity
Travel speed
(km/h)
90
Max.
Mi (Midium
speed)
80
Max.
3.3
4.4
Hi (High
speed)
100
Min.
5.5
2]
Automatic change by engine speed

If the fuel control dial is used to set the
engine speed to less than 1,200 rpm, the
travel speed changes to Lo when the
machine is travelling in Mi or Hi. and the
travel speed will not change to Mi or Hi.
3]
Automatic change by pump discharge

pressure
When traveling with the travel speed
switch set to Hi or Mi, if the load
increases, such as when travelling uphill,
and the travel pressure goes above 32.3
MPa {330 kg/cm2} for more than 0.5 sec,
the travel motor capacity will automatically
change to low speed (equivalent to Lo).
(The travel speed switch will stay at Hi or
Mi.)
If the load decreases, such as when travelling on level ground or travelling downhill, and the travel pressure goes below
18.6 MPa {190 kg/cm2} for more than 0.5
sec, the travel motor capacity will automatically change and will return to Hi or
Mi.
PC400, 450-7E0
8.
SEN03593-00
Attachment flow control and circuit selector function (if equipped)
Function
q
This function is available only with the attachment specification.
q
The function acts as follows according to the
flow command and working mode from the
monitor.
1) It throttles the attachment PPC pressure
and controls the flow when the pedal is
depressed fully.
2) In B mode and the other modes, it
switches to attachment single acting (B) or
double acting (other modes).
PC400, 450-7E0
29
SEN03593-00
9.
1)
System component parts

PPC oil pressure switch
1.
2.
3.
Plug
Switch
Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
0.5 0.1 MPa {5.0 1.0 kg/cm2}
Resetting (OFF) pressure:
0.3 0.05 MPa {3.0 0.5 kg/cm2}
Function
q
The junction block has 6 PPC oil pressure
switches.
q
This sensor detects the operating condition of
each actuator by the PPC pressure and transmit it to the pump controller.
30
PC400, 450-7E0
2)
Oil pressure sensor
1.
2.
Sensor
Connector
Function
q
The pump pressure sensor is installed to the
input circuit of the control valve.
q
It converts the pump discharge pressure into a
voltage and transmits it to the pump controller.
SEN03593-00
The relationship between the pressure applied

to sensors (P) and output voltage (E) is shown
in the figure below.
The amplifier magnifies output voltage (E) and

transmits it to the pump controller.
Operation
The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed.
q
The deformation in the diaphragm causes the
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage amplifier).
q
PC400, 450-7E0
31
SEN03593-00
3)
Pump pressure sensor (high pressure)
1.
2.
Sensor
Connector
Operation
q
The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
32
PC400, 450-7E0
4)
SEN03593-00
Pump controller
PC400, 450-7E0
33
SEN03593-00
CN-CP01
CN-CP02
Input/
Pin No.
Signal name
output
1
NC(*)
Input
2
R pump pressure sensor
Input
3
NC(*)
Input
4
NC(*)
5
NC(*)
Input
6
NC(*)
Input
7
NC(*)
Input
8
F pump pressure sensor
Input
9
NC(*)
Input
10
GND (SIG)
11
Knob switch
Input
12
NC(*)
Input
13
Bucket digging pressure sensor
Input
14
NC(*)
Input
15
NC(*)
Input
16
NC(*)
output
17
Key switch (C-terminal)
Input
18
NC(*)
Input
19
Arm digging pressure sensor
Input
20
NC(*)
Input
21
NC(*)
22
POT-PWR
output
23
Key switch (ACC-terminal)
Input
24
NC(*)
Input
occur.
Input/
output
1
NC(*)
output
2
Emergency swing parking switch
Input
3
NC(*)
Input
4
232C_RXD
Input
5
NC(*)
Input
6
NC(*)
Input
7
Machine select 4 (ATT)
Input
8
Service circuit SOL signal
output
9
NC(*)
output
10
NC(*)
Input
11
NC(*)
output
12
CAN_SH
13
Machine select 5 (ATT)
Input
14
232C_TXD
output
15
NC(*)
Input
16
Travel steering signal
Input
17
Machine select 3
Input
18
NC(*)
output
19
NC(*)
output
20
NC(*)
Input
Input/
21
NC(*)
output
Input/
22
CANO_L
output
Input/
23
NC(*)
output
24
FWE_switch
Input
25
NC(*)
Input
26
NC(*)
Input
27
Machine select 2
Input
28
NC(*)
Input
29
NC(*)
30
NC(*)
Input
31
NC(*)
Input/
32
CANO_H
output
Input/
33
NC(*)
output
34
GND (232C GND)
35
Service pressure switch
Input
36
NC(*)
Input
37
Machine select 1
Input
38
Swing prorix switch
Input
39
NC(*)
40
NC(*)
Input
occur.
34
Pin No.
Signal name
PC400, 450-7E0
SEN03593-00
CN-CP03
Input/
output
1
VB (Controller PWR)
Input
2
VIS (Solenoid PWR)
Input
3
SOL_COM (SOL. COM. GND)
4
Battery relay drive signal
output
5
NC(*)
output
6
LS-EPC
output
7
Travel junction solenoid
output
8
NC(*)
output
9
(Bucket digging pressure switch)
Input
10
Boom rise pressure switch
Input
11
VB (Controller PWR)
Input
12
VIS (Solenoid PWR)
Input
13
14
KEY_SIG
Input
15
NC(*)
output
16
PC-EPC
output
17
Merge divider solenoid
output
18
NC(*)
output
19
Bucket dump pressure switch
Input
20
Boom down pressure switch
Input
21
GND (Controller GND)
22
NC(*)
Input
23
24
KEY_SIG
Input
25
NC(*)
output
26
ATT currented
output
27
Travel speed solenoid
output
28
2-stage relief solenoid
output
29
Swing pressure switch
Input
30
(Arm digging pressure switch)
Input
31
32
33
34
NC(*)
35
NC(*)
output
36
NC(*)
output
37
Swing parking brake solenoid
output
38
NC(*)
output
39
Travel pressure switch
Input
40
Arm dump pressure switch
Input
occur.
Pin No.
PC400, 450-7E0
Signal name
35
SEN03593-00
Monitor system
36
The monitor system notifies the operator of

machine status. It monitors the condition of the
machine with sensors installed on various
parts of the machine, processes and immediately displays the obtained information on the
panel. The information that appears on the
panel is roughly divided as follows.
1. Alarms that are issued when the machine
has troubles
2. Machine status, including coolant temperature, hydraulic oil temperature and fuel
level
The machine monitor also has various mode
selector switches and functions to operate the
machine control system.
PC400, 450-7E0
SEN03593-00
Machine monitor
Outline
q
The machine monitor has the functions to display various items and the functions to select
modes and electric parts.
q
The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information.
q
The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC400, 450-7E0
37
SEN03593-00
Input and output signals

CN-1
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
CN-3
Signal name
Key ON
Key ON
Window washer motor output
Starting signal
Limit switch (W)
GND
GND
VB+
Wiper motor (+)
Wiper motor ()
Buzzer ON signal
Limit switch (P)
Input/
output
Input
Input
output
Input
Input
Input
output
output
Input
Input
CN-2
Input/
output
1
Engine coolant temperature
Input
2
Fuel level
Input
3
Radiator coolant level
Input
4
(Hydraulic oil level)
Input
5
Air cleaner clogging
Input
6
NC (*)
Input
7
Engine oil pressure
Input
8
Engine oil level
Input
Input/
9
Network signal
output
Input/
10
Network signal
output
11
Charge amount
Input
12
Hydraulic oil temperature (analog)
Input
13
GND (for analog signal)
14
Personal code relay
Output
15
Limit switch (window)
Input
16
Buzzer cancel
Input
17
Swing lock
Input
18
Preheating
Input
19
Light switch
Input
20
Network GND

occur.
Pin No.
38
Signal name
Input/
output
1
NC (*)
Input
2
NC (*)
Input
3
NC (*)
Input
4
NC (*)
Input
5
NC (*)
Input
6
NC (*)
Input
7
RS230C CTS
Input
8
RS230C RXD
Input
Input/
9
RS230C RXD
output
Input/
10
RS230C RXD
output
11
BOOTSW
Input
12
NC (*)
Input
13
GND
14
CAN (SHIELD)
Input
15
CAN (+)
Input
16
CAN ()
Input
occur.
Pin No.
Signal name
PC400, 450-7E0
SEN03593-00
Monitor control and display portion

Monitor portion
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Wiper monitor
Preheating monitor
Swing lock monitor
Engine coolant temperature monitor
Hydraulic oil temperature gauge
Engine coolant temperature gauge
Working mode monitor
Service monitor
Travel speed monitor
Fuel gauge
Fuel level monitor
Hydraulic oil temperature monitor
Power maximizing monitor
Auto-deceleration monitor
Engine oil pressure monitor
Charge level monitor
Radiator coolant level monitor
Engine oil level monitor
Air cleaner clogging monitor
Maintenance time warning monitor
PC400, 450-7E0
39
SEN03593-00
Monitor items and display

Symbol
Display item
Swing lock
Preheating
Power max.
Display method
Swing lock switch
Swing holding brake

release switch
Swing lock monitor
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Continuous set time
Preheating monitor status
Up to 30 sec.
ON
From 30 sec. to 40 sec.
Flashes
More than 40 sec.
OFF
Power max. switch status
Power max. monitor status
Being pressed
Lights up but goes out after approx.

9 sec. when kept pressed
Not being pressed
Flashes
Engine coolant
temperature
Hydraulic oil
temperature
See gauge display on the next page
Fuel level
40
PC400, 450-7E0
Gauge
Engine coolant
temperature (C)
Hydraulic oil
temperature (C)
Fuel level
(l)
PC400, 450-7E0
SEN03593-00
Range
Temperature or
volume
Indicator
Buzzer sound
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
467
Green
C2
381
Green
C3
295
Green
C4
147.5
Green
C5
114
Green
C6
80.5
Red
41
SEN03593-00
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Display item
Check before
starting item
When engine is
stopped
When engine is
running
Engine oil pressure
When abnormal,
lights up and buzzer
sounds
Battery charge
Lights up when
abnormal
Radiator coolant
level
Lights up when
abnormal
When abnormal,
lights up and buzzer
sounds
Engine oil level
Lights up when
abnormal
Lights up when
abnormal
Symbol
Maintenance
Lights up when there is a warning. Lights up

for only 30 sec. after key is turned ON, then
goes out.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil
Color of symbol
Low temperature
(Max. B6 or equivalent)
Black on
white background
Normal (B6 B2)
No display
High temperature
(Min. B2)
White on
red background
42
PC400, 450-7E0
Display category
Symbol
SEN03593-00
Display item
Wiper
Display range
INT
ON
Display method
OFF
Displays set condition
Working mode
Displays set
mode
Travel speed
Displays set
speed
Monitor
Service meter
PC400, 450-7E0
Auto-deceleration
ON OFF
Displays actuation status
Service meter
indicator
When service meter is working
Lights up when
service meter is
working
43
SEN03593-00
Switches
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
44
Working mode selector switch

Selector switch
Buzzer cancel switch
Display brightness, contrast adjustment switch
Control switch
Window washer switch
Wiper switch
Maintenance switch
Travel speed selector switch
Auto-deceleration switch
PC400, 450-7E0
Working mode selector switch

Press one of the P, E, B and L switches to set the
desired working mode. It is possible to check which
mode is active with the working mode monitor. The
relationship between each working mode and the
monitor display is shown in the table below.
Switch that
is pressed
Display
Working mode status

after setting
[P]
P mode (default)
[E]
E mode
[L]
L mode
[B]
B mode
Selector switch
This is used when making detailed settings in each
working mode. For details, see "Attachment flow
control function".
Buzzer cancel switch
Pressing this switch when the alarm buzzer is making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm buzzer
sounds.
Depending on the alarm buzzer type, it does not
stop even if you press the buzzer cancel switch.
Maintenance switch
Check the condition of the maintenance items. For
details, see "Maintenance function".
SEN03593-00
Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes as shown below.
OFF o INT o ON o OFF o..
The wiper settings can be viewed on the wiper
monitor. The relationship between the wiper setting
and the monitor display is shown in the table below.
Display
Setting
Wiper actuation status
None
OFF
Stowing stopped or
now stowing
Wiper symbol
+ INT
INT
Intermittent actuation
Wiper symbol
+ ON
ON
Continuous actuation
Window washer switch

While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
the wiper starts.
Control switch
This is used for control when using the maintenance function or select function. For details, see
each function.
Display brightness, contrast adjustment switch
This function is used to adjust the brightness and
contrast of the display. For details, see each function.
Auto-deceleration switch
The auto-deceleration switch toggles the autodeceleration function on and off. When the working
mode is switched, it is automatically set to ON.
When it is set to ON, the auto-deceleration monitor
appears.
Travel speed selector switch
Each time the travel speed selector switch is
pressed, the travel speed changes as shown
below.
Lo o Mi o Hi o Lo o..
The travel speed settings can be viewed on the
monitor. The relationship between the speed setting and the monitor display is shown in the table
below.
Display
Setting
Crawler symbol + Lo
Low speed (default)
Crawler symbol + Mi
Midium speed
Crawler symbol + Hi
High speed
PC400, 450-7E0
45
SEN03593-00
Select mode function

1.
q
q
Setting of oil flow

This is used when setting the flow in each
working mode.
It is available when genuine attachment piping
is installed and Attachment installed is
selected with the initial value setting function
on the service menu.
It is possible to check on the working mode
monitor if this function can be used.
Working mode
Monitor display
P mode
[P] + crusher symbol
E mode
[E] + crusher symbol
B mode
[B] + flow symbol
3)
Press control switch (2) and select the

flow level.
Control switch
Method of use
a Carry out the setting on the normal screen
P mode, E mode
1) Press select switch (1).
2)
When the screen changed as below,

select "01" by operating switch (2), and
press input confirmation switch (3).
4)
After completing the level selection, press

input confirmation switch (3). The selection flow level is confirmed and the screen
moves to the normal screen. When input
confirmation switch (3) is pressed, the
attachment flow is updated. The relationship between the flow level and the flow is
shown in the table below.
Flow level
8
7
6
5
4
3
2
1
a
46
Actuation
Flow level bar graph
extends to the right
retracts to the left
Flow (l/min)
550
476
401
327
253
179
104
30
Remarks
Default
Flow level is not changed until the

input confirmation switch is pressed.
It is, therefore, possible not to change
the flow level by pressing return
switch (4) to return to the normal
screen.
PC400, 450-7E0
SEN03593-00
B mode
6) When the screen changed as below,
select "01" by operation switch (2), and
press input confirmation switch (3).
7)
9)
After the flow level is confirmed, the

screen changes to the screen shown in
the diagram below. With this screen, it is
possible to make fine adjustment to the
flow.
Control switch
Select one of the three flow levels by moving the cursor with operation switch (2) or
entering the relevant number (01, 02 or
03) with the 10-key pad.
Actuation
10) Pressing input confirmation switch (3)

after selecting the flow level finalizes the
selection.
q
The relationship between flow level
and the flow is shown in the table
below.
Flow
level
8)
The relationship between the flow

level and the flow is shown in the
table below.
No.
Flow (l/min)
Remarks
01
230
Default
02
190
03
150
Pressing input confirmation switch (3)

after selecting the flow level finalizes the
selection.
a Flow level is not finalized until the
input confirmation switch is pressed.
Returning to the normal screen by
pressing return switch (4) will leave
the flow level setting unchanged.
PC400, 450-7E0
When flow When flow When flow

is 100 l/ is 140 l/ is 180 l/ Remarks
min.
min.
min.
200
280
360
180
260
340
160
240
320
140
220
300
120
200
280
100
180
260
80
160
240
Default
Flow level is not finalized until input

confirmation switch (3) is pressed.
Returning to the normal screen by
pressing return switch (4) will leave
the flow level setting unchanged.
47
SEN03593-00
11) Check the set value with the working

mode monitor. The relationship between
the display level and the set value is
shown in the table below.
2)
Display level
Set value (l/min.)
220 or 360
200 or 340
180 or 320
160 or 300
140 or 280
120 or 260
100 or 240
80
3)
The setting value adjusting screen shown

below is displayed. Operate operation
switch (2) to select the setting value.
Relationship between fuel mileage and
work rate for each of the setting values is
as follows.
E0: Initial Setting Value
(highest priority is placed on work
rate.)
E1: Economy Adjusting 1
(Priority is placed on work rate.)
(Priority is placed on fuel mileage.)
(highest priority is placed on fuel mileage.)
Adjusting E mode setting value

User can change a setting value on the E
mode to adjust engine power and enhance fuel
mileage on the E mode.
a
4)
2)
The screen shown below is displayed.

Operate operation switch (2) to select "02"
and then press input confirmation switch
(3).
5)
48
As the item goes lower, the fuel mileage is improved while, on the other
hand, the work rate is decreased.
Press input confirmation switch (3) to confirm the setting value.
Press return switch (4) to return to the

main screen.
PC400, 450-7E0
Maintenance function
SEN03593-00
1.
Method of checking maintenance items

1) Press maintenance switch (1) and switch
to the maintenance list display screen.
The maintenance items are displayed as
symbols on the screen.
2) Select one of the maintenance items by
moving the cursor with control switch (2)
or entering the relevant number (01 to 10)
with the 10-key pad.
a If the remaining time is less than 30
hours, the item is displayed in yellow,
and if it is less than 0 hours, it is displayed in red.
2.
Maintenance operation
1) After completing the selection, press input
confirmation switch (3). The screen will
change to the maintenance reset screen.
2) The maintenance reset screen shows the
time remaining before maintenance is
due. To reset the remaining time, press
input confirmation switch (3). When input
confirmation switch (3) is pressed, the
screen changes to the check screen. To
retun to the maintenance list screen, press
return switch (4).
This function alerts the operator when routine

maintenance (replacement, inspection or filling
for the 11 maintenance items) is due.
When maintenance switch (1) is pressed, any
maintenance item that is due is displayed yellow or red for 30 seconds.
The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
No.
Replacement interval
(Hours)
Item
01
Engine oil
500
02
Engine oil filter
500
03
Fuel main filter
1000
41
Fuel prefilter
04
Hydraulic filter
500
1000
05
Hydraulic tank breather
06
Corrosion resistor
500
1000(*)
07
Damper case oil
1000
08
Final case oil
2000
09
Machinery case oil
1000
10
Hydraulic oil
5000
*: If equipped (To be determined)

q
The content of the caution display differs

according to the remaining time. The relationship is as shown in the table below.
Display
Condition
None
Remaining time for maintenance for all items is more

than 30 hours
Notice display (black symbol displayed on yellow

background)
There is one or more items

with less than 30 hours
remaining time for maintenance
Warning display (white

symbol displayed on red
background)
There is one or more items

with less than 0 hours
remaining time for maintenance
PC400, 450-7E0
49
SEN03593-00
3)
4)
5)
50
The check screen shows the symbol for

the selected maintenance item and the set
time in large letters.
To reset the remaining time, press input
confirmation switch (3). The remaining
time is reset and the screen returns to the
maintenance list display screen. To retun
to the maintenance list screen without
resetting the remaining time, press return
switch (4).
On the maintenace list display screen, the
background color of the symbol for the
item where the maintenance item was
reset is the same as the background of the
screen.
PC400, 450-7E0
SEN03593-00
Brightness, contrast adjustment function
This function is used to adjust the brightness and

contrast of the display.
2)
3)
1.
Adjustment method
1) Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.
4)
Press operation switch (2), or use the 10key pad to input the number (01 02) to
select either contrast or brightness.
After completing the selection, press input
confirmation switch (3) to return to the
adjustment screen. Pressing return switch
(4) without pressing input confirmation
swith (3) or entering 00 with the 10-key
pad and then pressing input confirmation
switch (3) causes the screen to return to
the normal screen.
Press operation switch (2) and adjust the

brightness or contrast as desired.
Control switch
Actuation
Relationship between menu symbol

and content.
No.
Symbol
Content
00
Return mark
Return
01
Contrast
02
Brightness
PC400, 450-7E0
51
SEN03593-00
Service meter check function

q
52
With the starting switch in the OFF position,

pressing return switch (1) while holding down
operation switch (2) of the monitor for 3 to 5
seconds displays the service meter.
When the 2 switches are released, the display
goes out.
Display LCD check function

q
On the normal screen, if monitor return switch

(1) and working mode switch "P" (2) are kept
pressed at the same time, the whole screen
will become white. If any part of the display is
black, the LCD is broken.
PC400, 450-7E0
User code display function

q
If there is any problem in operating the

machine, the user code is displayed on the
monitor to advise the operator of the steps to
take. This code appears on the normal screen.
On the normal screen, the user code is displayed on the portion for the hydraulic oil temperature gauge in the center of the screen.
SEN03593-00
q
q
If there are more than one user codes, they are

displayed in turn every 2 seconds.
While the user code is being displayed, if the

input confirmation switch is pressed, the service code and failure code can be displayed.
Both service code and failure code identify the
cause of problem corresponding to the displayed user code.
PC400, 450-7E0
If there are more than one service or failure

codes, they are displayed in turn every 2 seconds.
Any service codes/failure codes that are not
related to the displayed user code is displayed
with this function.
If the telephone number has been set using the

service menu, the screen shows the service
code/failure code as well as telephone symbol
and telephone number. For details of inputting
the telephone number, see "Special functions
of monitor panel" in the "Testing and adjusting"
section.
53
SEN03593-00
Sensor
The signals from the sensors are input to the

monitor panel directly.
Either side of a sensor of contact type is
always connected to the chassis ground.
q
q
Sensor name
Type of
sensor
When
normal
When
abnormal
Hydraulic oil level
Contact
ON
(Closed)
OFF
(Open)
Hydraulic oil
temperature
Resistance
Coolant temperature
Resistance
Fuel level
Resistance
Contact
ON
(Closed)
OFF
(Open)
Hydraulic oil level sensor
1.
2.
3.
4.
54
Connector
Bracket
Float
Switch
PC400, 450-7E0
SEN03593-00
Hydraulic oil temperature sensor, coolant temperature sensor
1.
2.
3.
Thermistor
Body
Tube
Fuel level sensor
1.
2.
Float
Connector
PC400, 450-7E0
4.
5.
6.
Tube
Wire
Connector
3.
4.
Cover
Variable resistor
55
SEN03593-00
Air cleaner clogging sensor
56
PC400, 450-7E0
KOMTRAX terminal system
SEN03593-00
The KOMTRAX terminal system transmits various kinds of machine information wirelessly.
Persons to operate the KOMTRAX can refer to
the information at office to provide various
kinds of services for customers.
Information transmittable from the KOMTRAX
terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
PC400, 450-7E0
57
SEN03593-00
KOMTRAX terminal
1.
2.
3.
4.
DRC connector connection (40 poles)

(Do not connect any cable)
GPS antenna connection
Film antenna connection
The KOMTRAX terminal obtains various kinds

of machine information from the network signals and input signals in the machine and
transmits them via the wireless communication
antenna. It contains a CPU (Central Processing Unit) and has wireless communication
function and GPS function.
This terminal has an LED lamp unit and a 7segment display lamp unit used for inspection
and troubleshooting.
Input and output signals

DRC conector
Pin No.
Signal name
Input/output
1
6
CAN shield GND
7
CAN signal (L)
Input/output
8
CAN signal (H)
Input/output
9
S-NET shield GND
10
S-NET signal
Input/output
11
12
13
14
15
16
17
18
19
20
Relay output
output
21
Input for check
Input
22
Input for check
Input
23
24
25
*1: Never connect to NC or malfunctions or failures will

occur.
58
DRC conector
Pin No.
Signal name
Input/output
26
27
C-terminal input (Hi side)
Input
28
R-terminal input
Input
29
30
31
32
33
34
35
36
ACC input (analog)
Input
37
Power GND
38
Power GND
39
Regular power
Input
40
Regular power
Input
*1: Never connect to NC or malfunctions or failures will
occur.
PC400, 450-7E0
PC400, 450-7E0
SEN03593-00
59
SEN03593-00

2008 KOMATSU
All Rights Reserved
60
SEN03595-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts (Backhoe specification) .......................................................... 3
Standard value table for chassis related parts (Loading shovel specification).............................................. 12
PC400, 450-7E0
SEN03595-00
Standard value table for engine related parts

Applicable model
PC400, 400LC-7E0
PC450, 450LC-7E0
Engine
SAA6D125E-5
Item
Engine speed
Measurement conditions
Unit
Standard value
Permissible value
High idle
rpm
1,930 50
1,930 50
Low idle
rpm
1,000 25
1,000 25
Rated speed
rpm
1,900
1,900
kPa
{mmHg}
Min. 133
{Min. 1,000}
107 {800}
Max. 700
700
At sudden acceleration (Low o High)
%
{Bosch
index}
Max. 25 {Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Intake air pressure
At rated output
Exhaust gas
temperature
All speed range (intake air temp: 20C)
Exhaust gas color
Valve clearance
Normal
temperature
At low idle
MPa
Min. 1.18 {Min. 12}
{kg/cm2}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Compression pressure
Engine oil temperature: 40 60C

Engine speed: 200 250 rpm
MPa
{kg/cm2}
Min. 2.9 {Min. 30}
2.0 {200}
Blow-by pressure
At rated output
Engine coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 1.76
{Max. 180}
2.94 {300}
At rated output
Engine oil
temperature:
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18 {1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05 {0.5}
90 110
120
mm
13 16
13 16
EGR valve drive

pressure
Oil pressure
Oil temperature
At low idle
Engine oil
temperature:
Min. 80C
SAE0W30E0S,
SAE5W40E0S,
SAE10W30DH,
SAE15W40DH,
SAE30DH
engine oil
All speed range (inside oil pan)
Fan belt, alternator belt Deflection when pressed with finger force
tension
of approx. 98 N {10 kg}
PC400, 450-7E0
SEN03595-00
Standard value table for chassis related parts

1
(Backhoe specification)
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Engine speed
Category
Item
2 pumps at relief
Engine coolant temperature:

Within operating range
Engine at high idle
Arm in relief condition
At 2-pump relief + one

touch power up

Engine at high idle
Arm relief + power max. switch
in ON condition
Speed when autodeceleration is operated
Engine at high idle

Auto-deceleration switch in ON
condition
All control levers in NEUTRAL
condition
Boom control valve

Spool stroke
Arm control valve
Unit
Standard value
Permissible value
1,930 100
1,930 100
1,830 100
1,830 100
1,300 100
1,300 100
rpm
a b
Bucket control valve
mm
Swing control valve
9.5
9.5
0.5 0.5
9.5
9.5
0.5 0.5
Travel control valve

Travel of control levers
BLP00101
Boom control lever

Arm control lever
Bucket control lever
Swing control lever
Travel control lever
Engine stopped
At center of control lever grip
Max. reading up to stroke end
(excepting lever play in NEUTRAL position)
mm
Play of control levers
Operating effort of control levers
Boom control lever

Arm control lever
Swing control lever
Travel
control
PC400, 450-7E0
Lever
Pedal

Within operation range
Engine at high idle
N {kg}
85 10
85 10
85 10
85 10
85 10
85 10
85 10
85 10
115 12
115 12
Max. 10
Max. 15
15.7 4.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 4.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Category
Item
Unload pressure
Unit

Engine at high idle
Working mode: P mode
Hydraulic pump output pressure
with all control levers in NEUTRAL position
Standard value
Permissible value
4.2 1.0
{42 10}
4.2 1.0
{42 10}
34.81 +1.47
0.98
(37.27 +1.47
0.98 )
Boom
Hydraulic pressure
Arm
Bucket
Hydraulic oil
temperature:
Engine at high
idle
LOWER
RAISE
+15
{355 +15
10 (380 10 )}
{340 375 (365 400)}
At low-pressure setting
18.14 0.98
{185 10}
16.67 19.61
{170 200}
At highpressure
setting
31.38 1.47
{320 15}
29.2 33.34
{300 340}
34.81 +1.47
0.98
33.34 36.77
(35.79 39.23)
{340 375
(365 400)}

with all measurement circuits
relieved
Values inside parenthesis:
Hydraulic oil pressure with
power max. switch in ON mode
(reference only)
(37.27 +1.47
0.98 )
+15
{355 10 (380 +15
10 )}
30.89 +1.47
2.45
37.27 +2.94
0.98
{380 +30
10 }
33.34 36.77
(35.79 39.23)
{340 375
(365 400)}
27.95 32.85
{285 335}
35.79 40.70
{365 415}

Engine at high idle
output pressure with all control
levers in NEUTRAL position
3.24 0.2
{33 2}
2.84 3.43
{29 35}
When all
control
levers in
NEUTRAL
position
4.2 1.0
{42 10}
4.2 1.0
{42 10}
When traveling at half

stroke
(without
load)
2.65 0.1
{27 1}
2.65 0.1
{27 1}
2.9 +0.6
0.2
2.9 +0.6
0.2
{30 +5.5
1.5 }
{30 +5.5
1.5 }
Hydraulic oil temperature: Within

operation range
Engine at high idle
Working mode: P
LS differential pressure
mode
Traveling speed: Hi
Hydraulic oil pump
pressure LS
pressure
34.81 +1.47
0.98
{315 +15
25 }
Travel
PPC valve output

pressure
(37.27 +1.47
0.98 )
+15
{355 10 (380 +15
10 )}
MPa
{kg/cm2}
Swing
Control circuit source

pressure
33.34 36.77
(35.79 39.23)

Engine at high idle
Control lever full stroke
PC400, 450-7E0
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Category
Item
Swing brake angle
Unit
Standard value
Permissible value

Bucket: Empty
Engine at high idle
Swing circle misalignment amount
when stopping after one turn
deg.
(mm)
PC400: Max. 120

PC450: Max. 130
PC400: Max. 150

PC450: Max. 160
3.7 0.4
Max. 4.6
5.4 0.5
Max. 6.4
sec.
33.0 3.3
Max. 38
mm
90
Bucket: Empty
Engine at high idle
Time required for passing
points 90 and 180 from
starting point
sec.
180
Swing
Time taken to start

swing
Time taken to swing
Hydraulic drift of swing
PC400, 450-7E0

Bucket: Empty
Engine at high idle
Time required for 5 more turns
after making initial one turn

operation range
Engine stopped
Keeping upper structure transverse on slope of 15
Notching a mating mark on inner
and outer races of swing circle
Mating mark misalignment amount
during 5 minutes
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Swing
Category
Item
Leakage from swing

motor
Unit
Standard value
Permissible value
l/min
Max. 5.5
Max. 11
STD: 63.2 12.6

LC: 67.3 13.5
STD: 42.0 80.0

LC: 45.0 84.5
STD: 45.1 6.8

LC: 48.1 7.2
STD: 31.5 55.0

LC: 34.0 58.0
Hi
STD: 34.5 35
LC: 36.7 3.6
STD: 28.0 41.5

LC: 32.0 44.0
Lo
24.0 4.8
18.9 31.0
17.1 2.6
14.4 21.0
13.1 1.3
11.7 15.1
Max. 200
Max. 300

operation range
Engine at high idle
Swing lock switch: ON
Leakage amount for one minute
during swing relief
Lo
Travel speed
(Idle travel)
Travel
Travel speed
(Actual travel)
Travel deviation

Engine at high idle
Time required for track shoes
to make 5 turns after making
one initial idle turn

Engine at high idle
Flat ground
Time required for traveling 20
m after 10 m trial run
Mi
Mi
sec.
sec.
Hi

operation range
Engine at idle
Travel speed: Lo
Solid and flat ground
Swerving amount while traveling
20 m (X) after initial 10 m trial run.
mm
PC400, 450-7E0
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Category
Item
Hydraulic drift of travel
Standard value
Permissible value
mm
l/min
Max. 20
Max. 40
Travel

Engine stopped
Parking machine on slope 12 with
sprocket facing upslope
Sliding distance for 5 minutes
Hydraulic drift of work equipment

Engine at high idle
Leakage of travel motor
Travel: Lock sprocket.
Oil leakage amount for one minute
with traveling in relief condition
Work equipment
Unit
Whole work
equipment (tooth
tip fall amount)
Boom cylinder
(cylinder retraction amount)
Arm cylinder (cylinder extension
amount)
Bucket cylinder
(cylinder retraction amount)
PC400, 450-7E0
PC400: Max. 600 PC400: Max. 900

PC450: Max. 700 PC450: Max. 1,050

operation range
Flat and level ground
Work equipment in measurement
posture as illustrated above
Bucket load: 3,060 kg
Engine stopped
Work equipment control lever in
NEUTRAL position
Fall amount for 15 minutes as
measured every 5 minutes starting immediately after initial setting
PC400: Max. 25
PC450: Max. 29
PC400: Max. 38
PC450: Max. 44
PC400: Max. 85
PC450: Max. 100
PC400: Max. 128

PC450: Max. 150
PC400: Max. 30
PC450: Max. 35
PC400: Max. 45
PC450: Max. 53
mm
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
RAISE
Bucket
PC400: 4.0 0.4

PC450: 4.2 0.4
PC400: Max. 4.8

PC450: Max. 5.0
LOWER
Arm
Service limit value
PC400: 2.9 0.3

PC450: 2.8 0.3
PC400: Max. 3.4

PC450: Max. 3.3
CURL
Work equipment speed
Work equipment
Boom
Standard value for

new machine
PC400: 4.3 0.4

PC450: 4.7 0.5
PC400: Max. 5.0

PC450: Max. 5.4
DUMP
Item
3.6 0.4
Max. 4.3
CURL
Category
3.6 0.4
Max. 4.3
DUMP
Applicable model
2.9 0.3
Max. 3.5

Engine at high idle
Time required from raise
stroke end till bucket
touches ground

Engine at high idle
Time required from dumping stroke end to digging
stroke end

Engine at high idle
Time required from dumping stroke end to digging
stroke end
Unit
sec.
PC400, 450-7E0
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Category
Item
Time lag
Work equipment
Boom
Arm
Internal leakage
Bucket
Cylinders
Center swivel
joint
PC400, 450-7E0
Measurement Condition

Engine at low idle
Time required from raise stroke
end till bucket touches ground
and pushes up machine front

Engine at low idle
Time required from dumping
stroke end till bucket stops
momentarily after control lever
is tilted to digging and starts to
move again
Unit
Standard value
Permissible value
sec.
Max. 3.0
Max. 3.6
PC400: Max. 3.0

PC450: Max. 4.0
PC400: Max. 3.6

PC450: Max. 4.6
Max. 3.0
Max. 5.0
4.5
20
10
50
sec.

Engine at low idle
Time required from dumping
stroke end till bucket stops
momentarily after control lever
is tilted to digging and starts to
move again
Engine at high idle
Leakage amount for one
minute with cylinder or travel to
be measured in relief condition
cc/min
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Performance of
hydraulic pump
Performance in compound operation
Category
10
Item
Swerving amount in
simultaneous operation of work equipment and travel
Hydraulic pump
delivery
Engine at high idle
Traveling speed: Lo
Flat and level ground
Swerving amount (X) when
traveling 20 m after initial trial
run of 10 m
See next page
Unit
Standard value
Permissible value
mm
Max. 400
Max. 440
l/min
See next page
PC400, 450-7E0
SEN03595-00
PC400, 400LC-7E0
PC450, 450LC-7E0
Applicable model
Category
Item
Unit
Standard value
Permissible
value
Performance of hydraulic pump
Discharge amount of hydraulic pump (P mode)
Pump speed: At 1,950 rpm, PC current 280 mA
Check point
As desired
a
a
Test pump
discharge
pressure
(MPa {kg/cm2})
Discharge
pressure of
other pump
(MPa {kg/cm2})
P1
P2
Average
pressure
(MPa {kg/cm2})
P1+P2
2
Standard value
for discharge
amount Q
(l/min)
Judgement
standard lower
limit Q
(l/min)
See graph
See graph
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC400, 450-7E0
11
SEN03595-00
Standard value table for chassis related parts

1
(Loading shovel specification)

Applicable model
Engine speed
Category
Item
2 pumps at relief
At 2-pump relief + one

touch power up

Engine at high idle
Arm relief + power max. switch
in ON condition
Speed when autodeceleration is operated
Engine at high idle

Auto-deceleration switch in ON
condition
All control levers in NEUTRAL
condition
Spool stroke
Travel of control levers
Unit
Standard value
Permissible value
1,930 100
1,930 100
1,830 100
1,830 100
1,300 100
1,300 100
rpm
a b
Arm control valve

mm
Bucket control valve

Swing control valve
Travel control valve
9.5 9.5
0.5
0.5
9.5 9.5
0.5
0.5
BLP00101
Boom control lever
85 10
Max. 95
Min. 75
Arm control lever
85 10
Max. 95
Min. 75
85 10
Max. 95
Min. 75
85 10
Max. 95
Min. 75
115 12
Max. 127
Min. 103
Max. 10
Max. 15
15.68 3.92
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.68 3.92
{1.6 0.4}
Max. 24.5
{Max. 2.5}
12.74 2.94
{1.3 0.3}
Max. 21.56
{Max. 2.2}
12.74 2.94
{1.3 0.3}
Max. 21.56
{Max. 2.2}
24.5 5.88
{2.5 0.6}
Max. 39.2
{Max. 4.0}
74.48 18.62
{7.6 1.9}
Max. 107.8
{Max. 11}

Swing control lever
Engine stopped
(excepting lever play in NEUTRAL position)
mm
Travel control lever

Play of control levers
Operating effort of control levers
Engine at high idle
Arm in relief condition
Boom control valve
12
PC400-7E0
Work equipment,
swing
Boom control lever

Arm control lever
Swing control lever
Travel
control
Lever
Pedal

Engine at high idle
N {kg}
PC400, 450-7E0
SEN03595-00
Applicable model
Category
Item
PC400-7E0
Standard value
Permissible value
4.2 1.0
{42 10}
4.2 1.0
{42 10}
33.83 36.28
{345 370}
33.34 36.77
{340 375}
30.9 33.8
{315 345}
33.38 34.3
{310 350}
17.1 20.5
{175 210}
16.66 21.07
{170 215}
IN
31.8 34.3
{325 350}
31.36 34.79
{320 355}
OUT
31.8 34.3
{325 350}
31.36 34.79
{320 355}
CURL
32.3 34.79
{330 355}
31.85 35.28
{325 355}
DUMP
31.8 34.3
{325 350}
31.36 34.79
{320 355}
OPEN
31.8 34.3
{325 350}
31.36 34.79
{320 355}
MPa
CLOSE {kg/cm2}
29.9 33.3
{305 340}
29.4 33.81
{300 345}
Swing
30.89 +1.47
2.45
{315 +15
25 }
27.95 32.85
{285 335}
Travel
37.27 +2.94
0.98
{380 +30
10 }
35.79 40.70
{365 415}
3.24 0.2
{33 2}
2.84 3.43
{29 35}
When all
control levers
in NEUTRAL
position
4.2 1.0
{42 10}
4.2 1.0
{42 10}
When traveling at half

stroke
(without load)
2.65 0.1
{27 1}
2.65 0.1
{27 1}
2.9 +0.6
0.2
2.9 +0.6
0.2
Unload pressure
Unit

Engine at high idle
with all control levers in NEUTRAL position
RAISE
Arm
Hydraulic pressure
Bucket
LOWER
Boom
Oil temperature:
45 55C
Engine at full throttle
In heavy duty mode
Pump outlet port
pressure
Relive only circuit
being measured
Bottom dump
Control circuit source

pressure

Engine at high idle
output pressure with all control
levers in NEUTRAL position

operation range
Engine at high idle
Working mode: P
LS differential pressure
mode
Traveling speed: Hi
Hydraulic oil
pump pressure
LS pressure
PPC valve output
pressure
PC400, 450-7E0
At lowpressure
setting
At highpressure
setting

Engine at high idle
Control lever full stroke
{30 +5.5
1.5 }
{30 +5.5
1.5 }
13
SEN03595-00
Applicable model
Category
Item
PC400-7E0
Unit
Standard value
Permissible value
deg.
120
150
3.7 0.4
Max. 4.6
5.4 0.5
Max. 6.4
sec.
33.7 1.7
Max. 38
mm
Work equipment posture: Max. reach
Overrun when stopping

swing
45 55C
In H/O mode
Stop after swinging one turn and
measure distance that swing circuit moves
Work equipment posture:
Max. reach
90
Time taken to start
swing
sec.
45 55C
180
In H/O mode
Time taken to swing 90 and
180 from starting position
Swing
Work equipment posture: Max. reach
Time taken to swing

45 55C
In H/O mode
Swing one turn, then measure
time taken to swing next 5 turns
Hydraulic drift of swing Engine stopped

45 55C
Set machine on 15 slope, and
set upper structure at 90 to the
side
Make match marks on swing circle outer race and track frame
Measure distance that match
marks move apart after 5 minutes
14
PC400, 450-7E0
SEN03595-00
Applicable model
Swing
Category
Item
Leakage from swing

motor
PC400-7E0
Unit
Standard value
Permissible value
l/min
Max. 5.5
Max. 11
63.2 12.6
42.0 80.0
45.1 6.8
31.5 55.0
Hi
34.5 3.5
48.0 41.5
Lo
24.0 4.8
18.9 31.0
17.1 2.6
14.4 21.0
13.1 1.3
11.7 15.1
Max. 200
Max. 300

45 55C
Swing lock switch ON
Relieve swing circuit
Lo
Travel speed
(Idle travel)
Travel
Travel speed
(Actual travel)
Travel deviation

Engine at high idle
Time required for track shoes
to make 5 turns after making
one initial idle turn
Mi
Mi
Engine at high idle
Flat ground
Time required for traveling
20 m after 10 m trial run
sec.
sec.
Hi

45 55C
Travel speed: Hi
Run up for at least 10 m, and
measure deviation when traveling
next 20 m on flat ground
a Use a hard flat ground
mm
a Measure dimension ()
PC400, 450-7E0
15
SEN03595-00
Applicable model
Category
Item
Travel
Hydraulic drift of travel
Leakage of travel
motor
Engine stopped
45 55C
Stop machine on 12 slope with
sprocket facing straight up the
slope
Measure the distance that
machine moves in 5 minutes
PC400-7E0
Unit
Standard value
Permissible value
mm
l/min
Max. 20
Max. 40
Max. 600
Max. 900
Max. 25
Max. 38
Max. 85
Max. 128
Max. 30
Max. 45
Fit lock pin (1)

45 55C
Lock shoes and relieve travel circuit
Posture for measurement
16
Work equipment
Whole work
equipment (tooth
tip fall amount)
Boom cylinder
Place in above posture and mea(cylinder retraction
sure extension or retraction of
amount)
each cylinder and downward
movement at tip of bucket teeth
Bucket:
Rated load 21.2 kN {2,160 kg}
Arm cylinder
Horizontal flat ground
(cylinder extension Levers at neutral
amount)
Engine stopped
45 55C
Start measuring immediately after
Bucket cylinder
setting
(cylinder retraction Measure hydraulic drift every 5
amount)
minutes, and judge from results
for 15 minutes
mm
PC400, 450-7E0
SEN03595-00
Work equipment
Cylinder fully
retracted
Fully extended

45 55C
In A mode
RAISE
Arm
LOWER

45 55C
In A mode
Max. 5.7
3.7 0.4
Max. 4.5
CURL
Cylinder fully
extended
4.7 0.5
2.6 0.3
Max. 3.2
DUMP
Bucket teeth in
contact with ground
Permissible value
3.7 0.4
Max. 4.5
CURL
Boom
Standard value
5.2 0.6
Max. 6.4
DUMP
Item
3.5 0.4
Max. 4.3
OPEN
Category
PC400-7E0
1.9 0.2
Max. 2.3
CLOSE
Applicable model
Unit
2.1 0.3
Max. 2.7
sec.
Bucket
Cylinder fully
retracted
Fully extended

45 55C
In A mode
Bottom dump
Cylinder fully
retracted
Fully extended
PC400, 450-7E0

45 55C
In A mode
17
SEN03595-00
Applicable model
Category
Item
PC400-7E0
Unit
Boom
Standard value
Permissible value
Max. 3.0
Max. 5.0
Max. 3.0
Max. 5.0
Max. 3.0
Max. 5.0
Max. 3.0
Max. 5.0
Lower boom and measure time

taken from point where bucket
contacts ground to point where
chassis rises from ground
Engine at low idle
Hydraulic temperature: 45 55C
Arm
Time lag
Work equipment
Stop arm suddenly and measure

time taken for arm to stop
Engine at low idle
45 55C
sec.
Bucket
Stop bucket suddenly and measure time taken for bucket to stop
at bottom and then start again
Engine at low idle
45 55C
Bottom dump
Time taken for bottom dump to
move again when operated from
max. bottom open position to
close position and stopped temporarily
Engine at low idle
45 55C
18
PC400, 450-7E0
SEN03595-00
Applicable model
Performance in
compound operation
Item
Internal leakage
Work
equipment
Category
PC400-7E0
Unit
Cylinders

45 55C
Engine full throttle
Center swivel joint Relieve circuit to be measured
Standard value
Permissible value
Max. 4.5
Max. 20
Max. 10
Max. 50
Max. 400
Max. 440
cc/
min

45 55C
aUse a hard flat ground
aMeasure dimension ()
Swerving amount in
simultaneous operation
at work equipment and
travel
mm
Hydraulic pump
delivery
PC400, 450-7E0
Piston pump
Performance of
hydraulic pump
Oil temperature: 45 55C
See next page
l/min
See next page
19
SEN03595-00
Applicable model
Category
Item
PC400-7E0
Unit
Standard value
Permissible value
Performance of hydraulic pump
Discharge amount of hydraulic pump (P mode)
Pump speed: At 1,950 rpm, PC current 280 mA
Check point
As desired
a
a
20
Test pump
discharge
pressure
(MPa {kg/cm2})
Discharge
pressure of
other pump
(MPa {kg/cm2})
P1
P2
Average
pressure
(MPa {kg/cm2})
P1+P2
2
Standard value
for discharge
amount Q
(l/min)
Judgement
standard lower
limit Q
(l/min)
See graph
See graph
As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC400, 450-7E0
PC400, 450-7E0
SEN03595-00
21
SEN03595-00

2008 KOMATSU
All Rights Reserved
22
SEN03597-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Tools for testing, adjusting and troubleshooting.............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Measuring air boost pressure ......................................................................................................................... 8
Measuring exhaust temperature ..................................................................................................................... 9
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ..............................................................................................................................11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 15
Measuring engine oil pressure...................................................................................................................... 16
Measuring EGR valve and bypass valve drive pressure .............................................................................. 17
Handling fuel system parts............................................................................................................................ 18
Releasing residual pressure from fuel system .............................................................................................. 18
Measuring fuel pressure ............................................................................................................................... 19
Handling during cylinder cut-out operation ................................................................................................... 20
Handling during no injection cranking operation ........................................................................................... 20
Measuring fuel return rate and leakage ........................................................................................................ 21
PC400, 450-7E0
SEN03597-01
Bleeding air from fuel circuit.......................................................................................................................... 24

Checking fuel circuit for leakage ................................................................................................................... 25
Checking and adjusting fan belt and alternator belt tension ......................................................................... 26
Checking and adjusting air conditioner compressor belt tension .................................................................. 27
Measuring swing circle bearing clearance .................................................................................................... 28
Checking and adjusting track shoe tension................................................................................................... 29
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................................... 30
Measuring control circuit basic pressure....................................................................................................... 34
Checking and adjusting pump PC control circuit oil pressure ....................................................................... 35
Checking and adjusting pump LS control circuit oil pressure........................................................................ 38
Measuring solenoid valve output pressure.................................................................................................... 43
Measuring PPC valve output pressure.......................................................................................................... 46
Adjusting play of work equipment and swing PPC valves............................................................................. 47
Inspecting locations of hydraulic drift of work equipment.............................................................................. 48
Releasing residual pressure from hydraulic circuit........................................................................................ 50
Measuring oil leakage amount ...................................................................................................................... 51
Bleeding air from various parts ..................................................................................................................... 54
PC400, 450-7E0
SEN03597-01
Tools for testing, adjusting and troubleshooting

Testing and adjusting
item
Symbol
Measuring intake air pressure (boost pressure)
Measuring exhaust temperature
Measuring exhaust gas

color
Adjusting valve clearance

Measuring compression
pressure
Measuring engine oil pressure
799-101-1502 Digital thermometer
99.9 1,299C
799-201-9001 Handy smoke checker
Bosch index: Level 0 9
Commercially
Smoke meter
available
Commercially
Clearance gauge
available
795-502-1590 Compression gauge
795-471-1420 Adapter
6217-71-6112 Gasket
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
Pressure gauge:60 MPa {600 kg/cm2}
799-401-2320 Gauge
1
2
U
1
Measuring fuel pressure
2
3
Measuring fuel return rate

and leakage
Measuring swing circle

bearing clearance
Measuring and adjusting oil
pressure in work equipment, L
swing, and travel circuits
PC400, 450-7E0
101 200 kPa { 760 1,500

mmHg}
Measuring EGR valve drive

pressure
Remarks
799-401-2220 Hose
Q'ty
1
Measuring blow-by pressure
Part name
799-201-2202 Boost gauge kit
Part No.
0 7 MPa {0 70 kg/cm2}
For 125E-5 engine
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
799-401-2320 Gauge
Pressure gauge: 1 MPa {10 kg/cm2}
Adapter
8 1.25 mm o R1/8
Seal washer
795-471-1450
07005-00812
* Common with G1
6151-51-8490 Spacer
Inside diameter: 14 mm
6206-71-1770 Joint
Joint inside diameter: 10 mm
Commercially
Hose
available
5 mm 2 3 m
Commercially
Hose
available
15 mm 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
Commercially
Dial gauge
available
799-101-5220 Nipple
07002-11023
K
1
2
O-ring
With magnet
* Common with G1
Size: 10 1.25 mm
SEN03597-01

item
Measuring and adjusting
control circuit voltage

pressure in pump PC control circuit
Symbol
1
M
2
1
N
2
1

pressure in pump LS control O
circuit
2
3
1
Measuring solenoid valve

output pressure
2
3
Measuring PPC valve output pressure

Measuring oil leakage
Troubleshooting for/engine
controller/sensors/actuators
2
R
Part No.
Part name
Q'ty
799-101-5220 Nipple
07002-11023
O-ring
799-101-5220 Nipple
07002-11023
O-ring
799-101-5220 Nipple
07002-11023
O-ring
799-401-2701
Differential pressure
gauge
799-401-3100 Adapter
02896-11008
O-ring
* Common with G1
* Common with L2
* Common with G1
* Common with L2
* Common with G1
* Common with L2
* Common with G1
Size: 02
799-401-3200 Adapter
02896-11009
O-ring
Remarks
799-301-1740 Joint
Commercially
Measuring cylinder
available
799-601-4101
or
T-adapter assembly
799-601-4201
799-601-4130 T-adapter
Size: 03
* Common with G1
Size: PF1/4 + PT1/4
For Ne sensor
799-601-4150 T-adapter
For oil pressure sensor
799-601-4180 T-adapter
For EGR gas sensor
799-601-4211 T-adapter
For controller (50-pole)

(Except 799-601-4201)
799-601-4220 T-adapter

(Except 799-601-4201)
799-601-4240 Socket
For ambient pressure sensor
799-601-4250 Socket
For boost pressure sensor
799-601-4260 T-adapter
799-601-4330 Socket
For Bkup sensor
799-601-4350 T-box
For 60-pole type

(Except 799-601-4201)
795-799-5530 T-adapter
For coolant temperature sensor

For fuel temperature sensor
795-799-5540 T-adapter
For boost temperature sensor
799-601-9420 T-adapter
For common rail pressure sensor
799-601-9430 T-adapter
For supply pump PCV
PC400, 450-7E0

item
Troubleshooting for/engine
controller/sensors/actuators
Troubleshooting for chassis/

sensors/wiring harnesses
PC400, 450-7E0
SEN03597-01
Symbol
Part No.
Part name
Q'ty
799-601-4101
or
799-601-4201
or
T-adapter assembly
799-601-9000
or
799-601-9200
799-601-9020 T-adapter
For EGR valve solenoid

For bypass valve solenoid
For injector
799-601-9030 T-adapter
For EGR valve stroke sensor

For bypass valve stroke sensor
(Except 799-601-4101 and 799601-4201)
799-601-9000
or
799-601-9100 T-adapter assembly
or
799-601-9300
799-601-9310 Plate
799-601-9320 T-box
799-601-2500
or
799-601-2700
or
799-601-2800
or
T-adapter assembly
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 T-adapter box
For econo (Except 799-601-2700)
799-601-2740 Adapter for MIC
For MIC-5P
799-601-4101
or
799-601-4201
or
T-adapter assembly
799-601-9000
or
799-601-9200
799-601-9020 Adapter for DT
799-601-7000
or
799-601-7100
or
T-adapter assembly
799-601-7400
or
799-601-8000
799-601-7010 Adapter for X
For X1P (Except 799-601-7000 and

799-601-7100)
For X2P
For X4P
Remarks
For 24-pole type
For DT2P
SEN03597-01

item
Troubleshooting for chassis/

sensors/wiring harnesses
Symbol
Part No.
Part name
Q'ty
Remarks
799-601-7050 Adapter for SWP
For SW6P (Except 799-601-8000)
For SW8P (Except 799-601-8000)
For SW14P (Except 799-601-7000

and 799-601-7100)
799-601-7080 Adapter for M
For M1P (Except 799-601-7000

and 799-601-7100)
For M2P
For M3P
For M4P
For M6P
799-601-7140 Adapter for S
For S8P
For S12P (Blue) (Except 799-6018000)
For S16P (Blue)
799-601-7210 Adapter for AMP040
For A16P
For A20P
799-601-7520 Adapter for 070
799-601-9000
or
T-adapter assembly
799-601-9200
For 070-12P
For DT3P
799-601-9110 Adapter for DT (GR)
For DT12P (Gray)
799-601-9350 Adapter for DRC
For DRC40P
For DRC24P
799-601-7320 T-adapter for SWP
For AW16P
799-601-7340 T-adapter for M
For M8P
799-601-7360 T-adapter for relay
For REL-5P
799-601-7370 T-adapter for relay
For REL-6P
Out of kit
(No assembly No.)
Measuring wear on sprocket
796-627-1120 Wear gauge
Measuring coolant temperature and oil temperature
799-101-1502 Digital thermometer
99.9 1,299C
Measuring operating effort

and depressing force
79A-264-0021 Push-pull scale
0 294 N {0 30 kg}
79A-264-0091 Push-pull scale
0 490 N {0 50 kg}
Measuring stroke and

hydraulic drift
Commercially
Ruler
available
Measuring work equipment

speed
Commercially
Stopwatch
available
Measuring voltage and

resistance
Commercially
Circuit tester
available
PC400, 450-7E0
Measuring engine speed

1.
SEN03597-01
4)
Turn on the starter switch and then switch the

machine monitor display to Monitoring.
a For the operating method of the machine
monitor, see Special functions of machine
monitor.
a Monitoring code: 01002 Engine speed
01006 Engine speed
a Code 01002 represents the engine controller information and code 01006 represents the pump controller information.
Either of the codes is usable for the measurement.
a Engine speed is indicated in multiple of 1
r/min (1 rpm).
5)
2.
Start the engine and keep it running until temperature of the engine coolant and hydraulic oil
rise to the operating range.
3.
Measure the engine speed under the respective conditions listed below.
1) RPM at low idle:
1] Start the engine and set the fuel dial
to the low idle (MIN) position.
2] Set the work equipment, swing and
travel levers to the neutral position.
2) RPM at high idle:
to the high idle (MAX) position.
2] Set the working mode switch to Pmode.
3] Turn off the auto-deceleration switch.
3) Measuring the engine speed when 2pumps are relieved:
3] Put the arm in the IN relief position.
PC400, 450-7E0
Measuring the engine speed when 2

pumps are relieved and power maximizing
is turned on (near the rated speed):
3] Put the arm in IN relief position and
keep the power max. switch
depressed.
a The power maximizing function is
reset automatically in about 8.5 seconds even if the switch is being
depressed. Thus measurement of the
engine speed must be completed
within that period.
Measuring the speed when the autodecelerator is in operation:
2] Turn on the auto-deceleration switch.
a The engine speed will be slowed
down to a certain level in about 5 seconds from setting all levers in neutral.
This level is the engine speed when
operation of the auto-deceleration is
turned on.
SEN03597-01
Measuring air boost pressure

a
Part No.
4.
5.
Set the working mode switch to P-mode.
6.
Measure the intake air pressure (boost pressure) when the engine is set to high idle and
the boom RAISE side is relieved.
7.
Remove the measurement tool after the measurement, and make sure that the machine is
back to normal condition.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part of the

engine when removing or installing the measurement tools.
1.
Open the inspection cover of the engine hood

and remove intake air measuring plug (1).
a The plug removed can be any of the plug
provided on the right and left side.
Run the engine at middle or higher speed and

drain oil from the hose.
a When draining the oil, open the self seal of
the hose by inserting approximately half of
the gauge and hose connection. Repeat
operation until the oil is drained out.
a If Pm kit (A) is available, the air-bleeding
coupling (790-261-1130) in that kit may be
used.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
Air boost pressure measuring tools
Symbol
2.
3.
Install nipple [1] of the boost gauge kit A and

connect gauge [2] to it.
PC400, 450-7E0
SEN03597-01
Measuring exhaust temperature 1

a
A procedure of measuring periodical exhaust

temperature for preventive maintenance services (Pm clinic)
1) Set the working mode switch to P-mode.
2) Measure the exhaust temperature when
the engine is set to high idle and the arm
IN side is relieved.
a Measure and record the exhaust temperature after making sure it is stabilized.
6.
Measuring tools for exhaust temperature
Symbol
Part No.
799-101-1502
1.
5.
Part name
Digital thermometer
Before installing or removing the measuring tools, make sure the manifold temperature is sufficiently low.
Open the engine hood and remove the
exhaust temperature measuring plug (1).
2.
Install sensor [1] of digital thermometer B and

connect it to meter [2].
a Clamp the digital thermometer harness so
that it may not be accidentally contacted
against a hot part.
3.
4.
A procedure of measuring the maximum in

troubleshooting
Measurement of the maximum exhaust temperature must be done under actual working
conditions.
a PEAK mode of the digital thermometer
shall be used.
PC400, 450-7E0
SEN03597-01
Measuring exhaust gas color

a
Exhaust gas color measurement tools
Symbol
C
k
1.
Part No.
Part name
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter
Be careful not to touch the highly heated

parts, while removing and installing a measurement tool.
If no compressed air or power is not available
in the field, use Handy Smoke Checker C1. For
recording official data, use Smoke Meter C2.
Measurement with Handy Smoke Checker C1
1) Fit a filtering paper to Handy Smoke
Checker C1.
2) Insert the exhaust gas intake port to
exhaust pipe (1).
3) Start the engine and keep it running until
the engine coolant temperature rises to
the operating range.
4) Start the engine and accelerate it suddenly or run it at high idle and then operate the lever of smoke checker C1 in order
to suction exhaust gas to the filter paper.
5)
6)
2.
Take out the filtering paper and compare it

with the attached scale for judgement.
Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
Measurement with Smoke Meter C2

1) Insert probe [1] of smoke meter C2 to the
outlet of exhaust pipe (1) and fix it to the
exhaust pipe with a clip.
2)
3)
4)
5)
6)
7)
8)
9)
10
Connect the probe hose, accelerator switch

outlet and air hose to the smoke meter C2.
a Keep the pressure of the supplied compressed air at 1.5 MPa {15 kg/cm2} or
below.
Connect the power cable to an AC receptacle.
a Confirm that the smoke meter power
switch is in the OFF position, before
connecting the power cable to an outlet.
Loosen the cap nut of the suction pump
and fit in the filter paper.
a Fit the filtering paper securely so that
air may not leak.
Move the Smoke Meter C2 power switch
to the ON position.
Start the engine and keep it running until

the engine coolant temperature rises to
the operating range.
Let the exhaust gas stay on the filtering
paper by depressing the accelerator pedal of
Smoke Meter C2, when the engine speed is
suddenly accelerated or kept at high idle.
Put the polluted filtering paper on non-polluted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
PC400, 450-7E0
SEN03597-01
Adjusting valve clearance

a
Valve clearance adjustment tools
Symbol
Part No.
Commercially
available
1.
2.
Part name
Clearance gauge

and remove the head cover (1) of every cylinder.
a As for No.1 and 2 cylinders, remove the
air intake connector on the head cover,
too.
Remove the belt protection covers (two covers) and then loosen the tension of the fan belt
and alternator belt.
a The belts are loosened for confirming the
timing mark.
3.
Remove radiator under cover.
4.
Rotate the crankshaft forward to bring the

stamped 1.6 TOP line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Crank the crank shaft using the crank pulley mounting bolt (Bolt width: 24 mm). In
this case, turn the bolt in the normal rotation to prevent its loosening.
a When No. 1 cylinder is at the top dead
center, its rocker arm can be manually
moved as much as the valve clearance. If
it cannot be moved, that means that No. 1
cylinder is not yet at the top dead center.
In that case, rotate it by one more turn.
PC400, 450-7E0
5.
When No. 1 cylinder is at the top dead center,

adjust valve clearances indicated with a black
bullet mark in the chart below in the following
manner.
6.
Insert clearance gauge D in the clearance

between rocker arm (5) and crosshead (6) and
adjust the valve clearance with adjustment
screw (3).
a With the clearance gauge being inserted,
turn the adjustment screw until it allows
the clearance gauge to move slightly.
11
SEN03597-01
7.
While fixing adjustment screw (3), tighten locknut (4).

3 Locknut: 58.8 73.5 Nm {6.0 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
8.
12
It is also allowed to adjust respective cylinders in the firing order by turning the crank
shaft 120 at a time.
Firing order: 1 5 3 6 2 4
After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
3 Air intake connector clamp:
9.8 0.5 Nm {100 5 kgm}
a Adjust the belt tension referencing Testing and adjusting fan belt and alternator
belt tension.
PC400, 450-7E0
SEN03597-01
a
Measuring compression pressure1

a
Compression pressure measurement tools
Symbol
1
E
k
Part No.
Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).
Part name
795-502-1590
Compression gauge
795-471-1420
Adapter
6217-71-6112
Gasket
Be careful not to get burnt by touching the

exhaust manifold or muffler, or get caught
with a rotating parts, while taking measurement of compression pressure.
Before measuring the compression pressure,
make sure the engine is warmed up.
(Engine oil temperature: 40 60C)
1.
Run the engine for warm up until the engine oil

reaches 40 60C.
2.

and remove the head cover (1) of the cylinder
to be tested.
3.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See Adjusting valve clearance.
4.
Disconnect fuel high-pressure tube (3) and injector wiring harness (4) and remove injector (5).
a Before disconnecting the fuel high-pressure tube, loosen all center clamps.
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
PC400, 450-7E0
5.
Install adapter E2 to the injector mounting hole

and connect compression gauge E1 to it.
a Fit the gasket to the adapter end without
fail.
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6.
Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a See Adjusting valve clearance.
13
SEN03597-01
7.
Referencing Special functions of machine

monitor, set the no injection cranking and the
engine speed measurement mode.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
8.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
9.
After finishing testing, remove the testing tools

and return the removed parts.
a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
the following procedure.
1) Install the O-ring and gasket to injector
(11).
2) Fit holder (12) to injector (11) to temporarily assemble them as a unit to the cylinder head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
3 Spherical part of washer:
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut: 2.0 2.4 Nm {0.2 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
8) Tighten the clamping bolt of the fuel piping.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
14

3
Rocker arm assembly mounting

bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
Adjust the valve clearance.

For
details, see Adjusting valve clearance.
Cylinder head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
PC400, 450-7E0
SEN03597-01
Measuring blow-by pressure

a
Blow-by pressure measurement tools

.
Symbol
Part No.
799-201-1504
Part name
Blow-by checker
1.
Remove the engine under cover (1).
2.
Install nozzle [1] of blow-by checker F to blowby hose (1) and connect it to gauge [2] using
the hose.
3.
4.
Measure the blow-by pressure under the following conditions while setting the engine to
high idle.
q
Working mode: P-mode
q
Swing lock switch: ON (high pressure relief)
q
Work equipment, swing and travel: Arm IN
relief position
a Read off the blow-by pressure value,
when the needle of the gauge steadies
itself.
5.
PC400, 450-7E0
15
SEN03597-01
Measuring engine oil pressure

a
1
2
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Gauge
Run the engine until the engine coolant is

heated up to the operating range.
5.
Measure the engine oil pressure at low idle

and also at high idle.
6.

and remove the bracket (2) for clamping.
2.
Remove the oil pressure measurement plug

(1) on the cylinder block.
3.
Install nipple [1] of hydraulic tester G1 and connect it to gauge G2.
16
4.
Engine oil pressure measurement tools
Symbol
G
PC400, 450-7E0
SEN03597-01
Measuring EGR valve and bypass

valve drive pressure
1
a
Measuring instruments for EGR valve and

bypass valve drive pressure
Symbol
U
Part No.
799-101-5002
Hydraulic tester
790-261-1204
The measuring points may be different from

the following explanation, depending on each
applicable machine.
1.
Remove either of oil pressure pickup plugs (2)

of timing gear cover (1).
a If it is difficult to remove the pickup plug,
remove or move the following parts.
q
Remove the belt cover.
q
Remove the air conditioner compressor
belt.
q
Move the air conditioner compressor so
that it will not be an obstacle to the work.
Install nipple (Component of tool U: 790-3011190) to the oil pressure pickup hole.
PC400, 450-7E0
Connect hydraulic tester [1] to the nipple.
4.
Start the engine and measure the oil pressure

at low idle and high idle.
a When measuring without removing the
engine from the machine, measure under
the condition described in the shield
machine for the machine.
5.
After finishing measurement, remove the measuring instruments and return the removed
parts.
q
Replace the removed plug with new one.
When reusing it, remove the sticking gasket sealant from it with a wire brush and
apply new adhesive or gasket sealant to it
before installing.
2 Plug: LT-2 or LG-4
3 Plug: 16.7 37.2 Nm {1.7 3.8 kgm}
Part name
2.
3.
17
SEN03597-01
Handling fuel system parts

a
18
Precautions for checking and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When checking and maintaining the fuel system, take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used,
the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure from

fuel system
1
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit: Between Feed pump
Fuel filter Fuel supply
pump
High-pressure circuit: Between Fuel supply

pump Common rail
Fuel injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before checking the fuel system and installing
and removing its parts, the residual pressure in
the fuel system must be released completely.
Accordingly, observe the following.
Before checking the fuel system, or installing or removing its parts, wait at least 30
seconds after stopping the engine until the
residual pressure in the fuel system is
released. (Do not start the work just after
stopping the engine since there is residual
pressure.)
PC400, 450-7E0
SEN03597-01
Measuring fuel pressure

a
1
2
3
a
k
1.
3.
Testing tools for fuel pressure
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
(8 1.25 mm o R1/8)
07005-00812
Seal washer
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
4.
2.
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.
After finishing testing, remove the testing tools

and return the removed parts.
Install nipple [1] of adapter H3 and hydraulic

tester H1 and connect them to gauge H2.
PC400, 450-7E0
19
SEN03597-01
Handling during cylinder cut-out

operation
1
Handling during no injection

cranking operation
1.
2.
3.
20
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q
Leakage from the cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism (Moving valve
system)
q
Defect in electrical system
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to
find out a defective cylinder.
a See the section of Special functions of
machine monitor when turning on the cylinder cut-out operation.
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
engine unit has been stored for a long period,
the no-injection cranking is performed to lubricate the engine parts and protect them from
seizure.
See the section of Special functions of
machine monitor when turning on the no injection cranking operation.
PC400, 450-7E0
SEN03597-01
Measuring fuel return rate and leakage
Testing tools for leakage from pressure limiter

and return rate from injector
Symbol
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially
available
Hose
Commercially
available
Hose
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
1.
Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2)
3)
PC400, 450-7E0
Insert spacer J1 to return block (2) side

and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
Insert joint J2 to common rail (1) side and
retighten it with the currently removed joint
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
21
SEN03597-01
4)
Connect inspection hose J3 to the tip of

joint J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5)
3.
2.
22
Testing leakage from pressure limiter

1) Adjust routing to prevent its slacking of
inspection hose J3 and insert the hose
end to the oil pan (saucer).
2) Referencing Measuring engine speed,
set up the condition necessary for checking the engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
(rpm)
Leakage
(cc/min)
1,600
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injector.
a Disconnect both ends of the injector.
1) Disconnect fuel return hose (4) of return
block (2).
a Place a plug on the fuel hose side
and then fix it to the fuel tank.
Plug: 07376-70315
2)
Connect inspection hose J4 to return

block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
PC400, 450-7E0
3)
SEN03597-01
Adjust routing to prevent its slacking of

inspection hose J4 and insert the hose
end to the oil pan (container).
7)
4.
4)
5)
6)
Referencing Measuring engine speed,

set up the condition necessary for checking the engine speed.
Run the engine at the rated output.
After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed
(rpm)
PC400, 450-7E0
After finishing testing, stop the engine.
Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
Return (Spill) limit

(cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
23
SEN03597-01
Bleeding air from fuel circuit
If fuel is used up, or if a fuel circuit part is

removed or installed, bleed air from the fuel circuit according to the following procedure.
1.
Loosen plug (2) at the top of fuel main filter (1)

to remove plug (3).
a Don't touch fuel pre-filter (4). It is situated
in the suction side.
2.
Loosen lever-fixing butterfly screw (6) of priming pump (5) to remove it from the tap.
3.
Repeat priming by pressing lever (7) of the

priming pump until the fuel from plug (2)
becomes free from bubbles. Then install plug
(2).
4.
Continue priming one or two times to make

sure the fuel comes out of plug (1). Then
tighten plug (1).
5.
Then conduct approximately 20 times of additional priming and install butterfly screw (6) of
priming pump.
3 Butterfly screw tightening torque:
11.7 Nm {1.2 kgm}
24
PC400, 450-7E0
SEN03597-01
Checking fuel circuit for leakage 1
8.
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
Run the engine at high idle and load it.

a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil pressure from the hydraulic
pump.
9.
Inspect the fuel piping and devices for fuel

leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
a If no fuel leakage is detected, inspection is
completed.
1.
Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3.

leakage.
for fuel leakage.
and check again from step 1.
4.
Run the engine at low idle.
5.

leakage.
for fuel leakage.
6.
Run the engine at high idle.
7.

leakage.
for fuel leakage.
PC400, 450-7E0
25
SEN03597-01
Checking and adjusting fan belt

and alternator belt tension
1
4.
Slide alternator (7) by rotating adjusting nut

(6), adjust V belt (8) tension and tighten locknut (5).
a Nut (6):
q
Tightening the locknut clockwise
moves it to the belt-loosening side.
q
Tightening the locknut counterclockwise moves it to the belt-tightening
side.
a Check the pulleys for breakage, V-groove
for wear, V-belt for wear and contact of the
V-belt and V-groove for any trouble.
a A belt must be replaced with a new one
when it is elongated so as to eliminate the
adjustment allowance, or when cuts or
cracks are visible on it.
5.
Tighten mounting bolt (3) and fixing bolt (4).

a When a V-belt is replaced, adjust the tension again after operating the machine for
an hour.
Checking
1. Open the engine hood and remove the belt
protection covers (2 covers).
2.
Press the intermediate point of the belt

between fan pulley and compressor pulley with
a finger and measure deflection (a) of the belt.
a Deflection (a) when pressing force of
approx. 58.8 kg {approx. 6 kg} is applied:
Approx. 13 mm
Adjusting
a If the V belt deflection is abnormal, adjust it
according to the following procedure.
1.

and remove the bracket (1) and cover (2).
2.
Loosen mounting bolt (3) and fixing bolt (4).
3.
Loosen locknut (5).
26
PC400, 450-7E0
Checking and adjusting air

conditioner compressor belt
tension
SEN03597-01
2.
Loosen mounting bolt (2) and fixing bolt (3).
3.
Slide compressor (6) by loosening locknut (4)

and rotating adjusting nut, adjust V-belt (7) tension and tighten locknut (5).
a Check the pulleys for breakage, V-groove
for wear, V-belt for wear and contact of the
V-belt and V-groove for any trouble.
a A belt must be replaced with a new one
when it is elongated so as to eliminate the
adjustment allowance, or when cuts or
cracks are visible on it.
Tighten mounting bolt (2) and fixing bolt (3).
a When a V-belt is replaced, adjust the tension again after operating the machine for
an hour.
Checking
1. Open the engine hood and remove the belt
protection covers (2 covers).
2.
Press the intermediate point of the belt between

air compressor pulley and drive pulley with a finger and measure deflection (a) of the belt.
a Pressing force: Deflection (a) when pressing force of approx. 58.8 N {approx. 6 kg}
is applied: 14 16 mm
4.
Adjusting
a If the belt deflection is abnormal, adjust it
1. Open the inspection cover of the engine hood
and remove cover (1).
PC400, 450-7E0
27
SEN03597-01
Measuring swing circle bearing

clearance
1
a
3.
Set dial gauge to the zero point.
4.
Hold the arm nearly perpendicular to the

ground, and lower the boom until the track
shoes will be lifted at the machine front.
a The upper structure is raised at the front
and lowered at the rear at that time.
5.
From this state, read the dial gauge K value.

a The value indicated by dial gauge K is the
clearance of the bearing.
6.
Return the machine to the condition of step 2

and check that dial gauge K indicates zero
point.
a If zero value is not indicated, repeat the
steps in Items 3 through 5.
Swing circle bearing clearance measurement

tools
Symbol
Part No.
Commercially
available
a
k
1.
2.
28
Part name
Dial gauge
Follow the steps explained below when measuring clearance in the swing circle bearing on
the actual machine.
Be careful not to put a hand or foot under
the undercarriage, while taking measurement.
Fix dial gauge K to outer lace (1) or inner lace
(2) of the swing circle and contact the probe
against the end face of inner lace (2) or outer
lace (1) on the opposite side.
a Set dial gauge K in the front side or rear
side of the machine.
Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame.
a The upper structure is lowered at the front
and raised at the rear at that time.
PC400, 450-7E0
Checking and adjusting track

shoe tension
SEN03597-01
Checking
1. Run the engine at low idle and drive the
machine forward by the length of track on
ground, and then stop slowly.
2.
3.
Place steel bar [1] on the track shoe between

the idler (1) and the 1st carrier roller (2).
a L beam is recommended for bar [1]
because of its deflection-free nature.
Measure maximum clearance (a) between
steel bar [1] and track shoe.
q
Standard maximum clearance (a): 10 30 mm
PC400, 450-7E0
Adjusting
a If the track shoe tension is not proper, adjust it
in the following manner.
1.
When the tension is too strong

Loosen valve (3) to discharge the grease.
k Do not loosen the valve more than 1
turn. Otherwise, the valve may jump
out because of the high- pressure
grease inside.
2.
When the tension is too weak

Add grease through valve (3).
a If the normal track shoe tension is not
restored even after greasing, move the
machine slowly back and forth.
29
SEN03597-01

pressure in work equipment,
swing, and travel circuits
a
Measuring and adjusting tools for hydraulic oil

pressure in hydraulic circuit for work equipment, swing and travel
Symbol
1
L
2
q
q
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
Nipple (10 1.25 mm)
07002-11023
O-ring
The oil pressure in the work equipment, swing,

and travel circuits can be checked with monitoring function of the monitor panel, too (For
details, see Special functions of monitor
panel).
Monitoring code: 01100 F pump pressure
01101 R pump pressure
Pump oil pressure is indicated in multiples of
1 MPa (1 kg/cm2, 1PSI).
2)
Fit nipple L2 and connect it to oil pressure

gauge [1] of hydraulic tester L1.
a The oil pressure gauges used shall
be 60 MPa {600 kg/cm2}.
3)

the hydraulic oil pressure rises to the
operating range.
Measuring
1. Preparation work
k Lower the work equipment to the
ground and, after stopping the engine,
release residual pressure in the piping
by operating the control lever several
times. Then loosen the oil filler cap
gradually to release pressure inside
the tank.
1) Open the pump room cover and remove
oil measuring plugs (1) and (2).
q
q
30
(1): Front pump discharge pressure

measuring plug
(2): Rear pump discharge pressure
measuring plug
PC400, 450-7E0
2.
SEN03597-01
Combination of pump, actuator, and valve

a When the oil from the pumps is divided,
the front pump and rear pump act independently on each actuator. Note that different actuators relieve different valves.
a When the work equipment circuit or swing
circuit is relieved singly, the oil of the
pumps is diverted.
a The actuators in the table are arranged in
the order when the control valve is seen
from the front of the machine.
Pump
Actuator
5.
Measurement of swing relief pressure

1) Start the engine and move the swing lock
switch to the ON position.
2) Measure hydraulic oil pressure when the
engine is running at high idle and the
swing circuit is relieved.
a Hydraulic oil pressure when the swing
motor safety valve is relieved is displayed.
a The relief pressure of the swing motor
is lower than the main relief pressure.
6.
Measurement of travel circuit relief pressure

1) Start the engine, and lock the travel.
k Insert pin [2] between the sprocket
and the track frame to positively
lock the travel circuit.
Valve relieved
(F unload valve) (F main relief valve)
Front
Service
Safety valve for service
Boom Hi
Arm Hi
F main relief valve
Bucket
F main relief valve
Left travel F main relief valve

Boom
Turning on the swing lock switch

always turns on the 2-stage relief
solenoid valve, causing the high-pressure relief. Accordingly, keep the
swing lock switch turned OFF.
Raise: F main relief valve

Lower: Safety-suction valve
(Pump merge-divider valve) (Travel junction valve)

(Self pressure reducing valve)
Swing
Rear
Swing motor safety valve
Right travel R main relief valve

Arm Lo
R main relief valve
(R unload valve) (R main relief valve)

(Centralized safety valve) (Back pressure valve)
3.
4.
Measurement of unload pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position.
a Hydraulic oil pressure when the
unload valve unloads is displayed.
Measurement of work equipment relief
pressure
1) Start the engine and move the cylinder to
be measured to its stroke end.
2) Measure hydraulic oil pressure when the
cylinder is relieved while the engine is running at high idle.
a The pressure measured when the
main relief valve is relieved is indicated.
a If the power maximizing switch is
released, the main relief valve is
relieved at low pressure. If the former
is pressed, the latter is relieved at
high pressure.
PC400, 450-7E0
2)
Measure the pressure when the engine is

set to high idle and the travel circuit is
relieved.
a Hydraulic oil pressure with the main relief
valve in relief condition is displayed. In
the travel circuit relief, the pressure is
high pressure relief all the time.
Adjusting
a Adjustment of the unload valve is not available.
1.
Adjustment of main relief pressure

a When the relief pressure of the work
equipment circuit or travel circuit is abnormal, adjust main relief valves (3) and (4)
q
(3): Front main relief valve
q
(4): Rear main relief valve
a When adjusting the main relief valve on
the front pump side, remove the top cover
of the control valve.
31
SEN03597-01
a
1)
2)
3)
4)
5)
6)
32
When adjusting the main relief valve on

the rear pump side, remove the under
cover of the control valve (when it is
installed).
As for the main relief valve, be sure to
adjust its low-pressure relief pressure
alone (adjusting the low-pressure relief
pressure automatically sets the high-pressure relief pressure, too.).
When the low-pressure relief pressure is
turned on, the 2-stage relief valve is OFF
and thus the pilot pressure is not applicable to the switching port.
Disconnect pilot hose (5).

While fixing holder (6), loosen locknut (7).
Turn holder (6) to adjust the pressure.
a Turning the holder clockwise increases
the pressure. Turning it counterclockwise decreases the pressure.
a Quantity of adjustment per turn of
holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
While fixing holder (6), tighten locknut (7).
3 Locknut: 49.0 58.8 Nm {5 6 kgm}
2.
Adjustment of boom LOWER relief pressure

(on the side where high pressure is set)
a If the high relief pressure for boom
LOWER is not normal, adjust the high
pressure set side of safety-suction valve
(8) for boom LOWER according to the following procedure.
a The high-pressure relief pressure mode
denotes the state in which the machine
push-up switch is turned on, disabling to
apply the pilot pressure to the switching
port.
1)
2)
3)
4)
Disconnect pilot hose (9).

While fixing holder (10), loosen locknut
(11).
Turn holder (10) to adjust the pressure.
holder:
While fixing holder (10), tighten locknut
(11).
3 Locknut:
93 123 Nm {9.5 12.5 kgm}
Connect pilot hose (5).

Check the pressure again after the adjustment, following the aforementioned steps
for measurement.
PC400, 450-7E0
5)
6)
3.

for measurement.
a Adjusting the high pressure set side
changes setting of the low pressure
side. Thus, this side requires adjustment, too.
Adjustment of boom LOWER relief pressure

(on the side where low pressure is set)
a When the low relief pressure for boom
LOWER is not normal or when the high
pressure set side was adjusted, adjust the
low pressure side of safety-suction valve
(8) for boom LOWER according to the following procedure.
a The low-pressure relief pressure mode
denotes the state in which the machine
push-up switch is turned off, disabling to
apply the pilot pressure to the switching port.
1) Disconnect pilot hose (9).
2) While fixing holder (12), loosen locknut
(13).
3) Turn holder (10) to adjust the pressure.
holder:
4) While fixing holder (12), tighten locknut
(13).
3 Locknut 78 93 Nm {8.0 9.5 kgm}
5)
6)

for measurement.
PC400, 450-7E0
SEN03597-01
4.
Adjustment of swing relief pressure

a If the swing relief pressure is abnormal,
adjust safety valve (14) of the swing motor
1)
2)
3)
4)
While fixing adjusting screw (15), loosen

locknut (16).
Turn adjustment screw (15) to adjust the
pressure.
a Adjustment screw:
q
Turning it clockwise increases
the pressure.
q
Turning
it
counterclockwise
decreases the pressure.
adjusting screw:
4.70 MPa {47.9kg/cm2}
While fixing adjustment screw (15), tighten
locknut (16).
3 Locknut:
147 196 Nm {15 20 kgm}
for measurement.
33
SEN03597-01
Measuring control circuit basic

pressure
1
a
Control circuit oil pressure inspection and

adjustment tools
Symbol
1
M
2
Part No.
3.
Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
4.
Measure hydraulic oil pressure, when the

engine is running at high idle and all the control
levers are moved to the NEUTRAL position.
5.
a It is not allowed to adjust the relief valve of
the control circuit source pressure.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
Nipple (10 1.25 mm)
07002-11023
O-ring
Measuring
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pressure inside the tank.
1.
2.
34
Remove the top cover of the control valve and

remove plug (1) for measuring the control circuit basic pressure.
a The figure shows the control valve side
viewed from inside the pump room.
Install nipple M2 and connect it to oil pressure

gauge [1] of hydraulic tester M1.
a Use the oil pressure gauge with capacity 6
MPa {60 kg/cm2}.
PC400, 450-7E0
SEN03597-01
Checking and adjusting pump PC

control circuit oil pressure
1
a
2)
Pump PC control circuit oil pressure checking

and adjusting tools
Symbol
1
N
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
Nipple (10 1.25 mm)
07002-11023
O-ring
Measuring
a Measurement of the oil pressure in the pump
PC control circuit shall be conducted after
making sure that oil pressure of the work
equipment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
1.
Measurement of PC valve output pressure

(servo piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each
other.
oil pressure measuring plugs (1), (2), (3)
and (4).
q
measuring plug
q
measuring plug
q
(3): Front PC valve output pressure
measuring plug
q
(4): Rear PC valve output pressure
measuring plug
PC400, 450-7E0
Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauge with
capacity 60 MPa {600 kg/cm2}.
q
The figure shows the pump discharge
pressure side.
3)
The figure shows the PC valve output

side.

the hydraulic oil temperature rises to the
operating range.
35
SEN03597-01
4)
Measure the pump discharge pressure

and PC valve output pressure (pressure at
servo piston inlet) at the same time after
setting following conditions with the
engine running at high idle.
q
q
(Turning 2-stage relief ON induces
high-pressure relief)
q
Work equipment, swing and travel:
Arm IN relief
a Method of judgment:
If the following ratio is obtained
between the pump discharge pressure and PC valve output pressure
(servo piston output pressure), the
PC valve is normal.
Measured oil
pressure
Oil pressure ratio
Pump discharge
pressure
PC valve output
pressure
Approx. 0.6
(Approx. 3/5)
2)
Install nipple N2 and connect it to oil pressure gauge [1] of hydraulic tester N1.
be 6 MPa {60 kg/cm2}.
3)

operating range.
4)
Measure the hydraulic oil pressure with all

the control levers kept in the NEUTRAL
position and the engine running at high
idle and at low idle.
a You can assume that the PC-EPC
valve output pressure is normal when
the following changes are observed.
5)
2.
If there is any abnormality with PC

valve or servo piston, the PC valve
output pressure (servo piston output
pressure) becomes identical with the
pump discharge pressure or comes to
neighborhood of 0 pressure.
Measurement of PC-EPC valve output pressure

PC-EPC valve output measuring plug (5).
Engine
Control
lever
Low idle
Neutral
High idle
5)
36
Oil pressure
2.94 MPa
{30 kg/cm2}
0 MPa
{0 kg/cm2}

PC400, 450-7E0
Adjusting
a If either of the following phenomena occurs
and the PC valve seems to be defective, adjust
PC valves (6) and (7) according to the procedure shown below.
q
As the working load increases, the engine
speed decreases remarkably.
q
The engine speed is normal but the work
equipment speed is low.
q
(6): Front pump PC valve
q
(7): Rear pump PC valve
a The width across flats of the PC valve
locknut is 13 mm and that of the adjustment screw (inside width) is 4 mm. Do not
turn any other locknuts or adjustment
screws since they affects the hydraulic
pump performance.
1.
Loosen locknut (8).

a Before loosening the locknut, make
counter mark at the adjustment screw end
so that you can see the position of the
locknut before the adjustment (and you
can return the locknut to its original position after turning it in reverse).
2.
Turn adjustment screw (9) clockwise or counterclockwise to adjust.

a Adjustment screw:
q
Turn it clockwise when the work
equipment speed is low (to increase
pump absorption torque).
q
Turn it counterclockwise when the
engine speed lowers (to decrease
pump absorption torque).
a Following indicates the range of adjustment available from the adjusting screw.
q
Counterclockwise: Within 1 turn
q
Clockwise: Within 1 turn
PC400, 450-7E0
SEN03597-01
3.
Tighten locknut (8).

3 Locknut: 27.5 34.3 Nm {2.8 3.5 kgm}
4.
After the adjustment, make sure that the PC

valve output pressure (servo piston inlet pressure) is normal using the measurement steps
explained earlier.
37
SEN03597-01
Checking and adjusting pump LS

control circuit oil pressure
1
a
Pump LS control circuit oil pressure checking

and adjusting tools
Symbol
1
O
2)
2
3
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
Nipple (10 1.25 mm)
07002-11023
O-ring
799-401-2701
Differential pressure gauge
Measuring
a Measurement of the oil pressure in the pump
LS control circuit shall be conducted after making sure that oil pressure of the work equipment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
1.
38
Measuring LS valve output pressure (servo

piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each other.
1) Remove oil pressure measuring plugs (1),
(2), (3) and (4).
q
measuring plug
q
measuring plug
q
(3): Front pump LS valve output
pressure measuring plug
q
(4): Rear pump LS valve output pressure measuring plug
Install nipple O2 and connect it to oil pressure gauge [1] of hydraulic tester O2.
be 60 MPa {600 kg/cm2}.
q
pressure side.
3)
The figure shows the LS valve output

side.
Run the engine until the hydraulic oil temperature reaches the operating range and
then push up the measurement side track
shoe with the work equipment.
q
When measuring the front circuit:
Left track shoe
q
When measuring the rear circuit:
Right track shoe
k Provide a working area of sufficient space, as the raised track
shoe will be idly rotated.
PC400, 450-7E0
SEN03597-01
2.
4)
Measurement of LS differential pressure

a LS differential pressure can be obtained
by measuring the pump discharge pressure and LS pressure (actuator load pressure) at the same time and computing the
difference between the two pressures.
oil pressure measuring plugs (1), (2), (5)
and (6).
q
measuring plug
q
measuring plug
Measure the pump discharge pressure

and LS valve output pressure (pressure at
servo piston inlet) at the same time after
setting following conditions with the
engine running at high idle.
q
q
When all levers are at neutral and
when travel lever is at half stroke (one
side of travel is at idle)
a Let the raised track shoe idly rotate,
paying enough attention to the surroundings for safety.
a Judgement method:
When the ratio between the pump
discharge pressure and LS valve output pressure (servo piston output
pressure) reaches the following values, both pressures are judged normal.
q
q
(5): Front pump LS pressure measuring plug

(6): Rear pump LS pressure measuring plug
Oil pressure ratio

Measured oil
pressure
Pump discharge
pressure
LS valve output
pressure
5)
All levers
at neutral
Almost
same
pressure
Travel lever
moved halfway
1
Approx. 0.6
(Approx. 3/5)

PC400, 450-7E0
2)
Install nipple O2 and connect it to the oil

pressure gauge of differential pressure
gauge O3 or hydraulic tester O1.
a When using differential pressure
gauge:
Connect the pump discharge pressure to the high pressure side (back
side) and LS pressure to the low
pressure side (bottom side).
The diffe rential press ure gauge
needs 12 DCV power. Thus connect a
battery to it.
39
SEN03597-01
a
When using the oil pressure gauge:

The oil pressure gauges used shall
be 60 MPa {600 kg/cm2}.
Differential pressure is approximately
2.9 MPa {30 kg/cm 2 } at maximum.
Thus measure the pressure reconnecting the same gauge.
pressure side.
4)
The figure shows the LS pressure

side.
Measure the pump discharge pressure and

LS pressure (actuator load pressure) at the
same time after setting the following conditions with the engine running at high idle.
q
q
Travel speed: Hi
q
When all levers are at neutral and
when travel lever is at half stroke (one
side of travel is at idle)
a Let the raised track shoe idly rotate,
paying enough attention to the surroundings for safety.
a Calculating LS differential pressure
(When the oil pressure gauge is
used):
LS differential pressure = Pump discharge pressure LS pressure
a If LS differential pressure is in the following conditions, it is judged normal.
Operation of levers
LS differential
pressure
Unload pressure
When all levers at neu(See Standard
tral
value table)
3)
40
Run the engine until the hydraulic oil temperature reaches the operating range and
then push up the measurement side track
shoe with the work equipment.
q
When measuring the front circuit:
Left track shoe
q
When measuring the rear circuit:
Right track shoe
k Provide a working area of sufficient space, as the raised track
shoe will be idly rotated.
Maximum LS
differential presTravel lever moved
sure
halfway (Travel at idle)
(See Standard
value table)
5)

PC400, 450-7E0
3.
Measurement of LS-EPC valve output pressure

LS-EPC valve output measuring plug (7).
2)
3)
Install nipple O2 and connect it to oil pressure gauge [1] of hydraulic tester O1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.
SEN03597-01
4)
5)
Measure the oil pressure when the engine

is running at high idle and the travel speed
switch and travel control lever are operated.
a If LS-EPC valve output pressure
changes to the following values, the
pressure is normal.
Travel
speed
Travel lever
Oil pressure
Lo
Neutral
Approx. 2.94 MPa

{Approx. 30 kg/cm2}
Hi
Fine travel
lever control
(Note)
0 MPa {0 kg/cm2}
Note: Operate the travel control lever

slightly to the extent that the PPC oil
pressure switch is turned ON (Stop
the operation short of starting the
machine).

operating range.
PC400, 450-7E0
41
SEN03597-01
Adjusting
a If the LS differential pressure is abnormal,
adjust LS valves (8) and (9) according to the
q
(8): Front pump LS valve
q
(9): Rear pump LS valve
1.
While fixing adjusting screw (10), loosen locknut (11).
2.
Turn adjusting screw (10) to adjust the pressure.

a Adjustment screw
q
Turned to the right, the differential
pressure is increased.
q
Turned to the left, the differential
pressure is decreased.
a Quantity of adjustment per turn of adjustment screw (LS differential pressure):
1.3 MPa {13.3 kg/cm2}
3.
After the adjustment, confirm that LS differential pressure is normal, following the steps for
measurement explained earlier.
42
PC400, 450-7E0
SEN03597-01
Measuring solenoid valve output

pressure
1
2.
Install adapter P2 or P3 and connect the currently disconnected hose again.
3.
Install nipple [1] of hydraulic tester P1 and connect it to oil pressure gauge [2].
a Use the oil pressure gauge with capacity 6
MPa {60 kg/cm2}.
a Figure shows the outlet hose of the 2stage solenoid valve being installed with
the measuring tool.
4.

range.
5.
Run the engine at high idle and operate the control levers and switches to turn the solenoid valve
ON or OFF. Measure the oil pressure when the
valve is turned on and also when turned off.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing
Table for functioning conditions for each
solenoid valve.
a The operating condition of the solenoid
valve can be checked with the monitoring
function of the machine monitor (For the
operating procedure, see Special functions of machine monitor.
Solenoid valve output pressure measurement

tools
Symbol
1
P
2
3
a
k
1.
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3100
Adapter (Size 02)
02896-11008
O-ring
799-401-3200
Adapter (Size 03)
02896-11009
O-ring
Measure the solenoid valve output pressure

after confirming that the control circuit source
pressure is normal.
Lower the work equipment to the ground
Remove the control valve top cover and disconnect outlet hoses (1) to (7) of the target
solenoid valve of measurement.
a A quick coupler is attached to the solenoid
valve of PPC lock solenoid valve's outlet
hose. Thus, measurement shall be conducted on PPC valve side (back side of
operator's cab).
No.
1
Solenoid valve to be measured

Swing holding brake solenoid valve
Travel speed shifting solenoid valve
PPC lock solenoid valve
PC400, 450-7E0
43
SEN03597-01
a
6.
When each output pressure shows the following values, it is judged normal.
Solenoid valve
Output pressure
OFF (De-energized)
0 MPa {0 kg/cm2}
ON (Energized)
Almost the same pressure as the control circuit basic pressure (See
Standard values table)
Table for functioning conditions 2-stage relief solenoid valve

Operation
Operating condition
Overheat 1st setting is ON
OFF
All of work equipment, swing, and travel signals are OFF

Swing lock switch is ON
Travel signal is ON
L-mode is selected
ON
Boom LOWER signal is ON

P or E-mode is selected
Left knob switch is ON
Signals other than the swing single are ON

Swing single is ON
OFF
Other than above conditions
Table for functioning conditions machine push up solenoid valve

Operation
Operating condition
Machine push-up switch
OFF
ON
ON
OFF
Table for functioning conditions Swing holding brake solenoid valve

Operation
Operating condition
Work equipment, swing, and travel signals
44
All are OFF
OFF
Any one is ON
ON
PC400, 450-7E0
SEN03597-01
Table for functioning conditions Travel speed shifting solenoid valve

Operation
Operating condition
Overheat 2nd setting is ON
Fuel control dial is at 1,200 rpm or below
Travel speed switch is at Lo
OFF
Travel signal is OFF

Travel speed switch is at Mi or Hi
Travel signal is ON
F or R pump pressure is at 32.3 MPa {330 kg/cm2} or

above
F or R pump pressure is at 18.6 MPa {190 kg/cm2} or
below
ON
Table for functioning conditions Merge/divide solenoid valve

Operation
Operating condition
When B mode is
selected
Service single ON
Travel is operated single
ON
2
F or R pump pressure is at 19.6 MPa {200 kg/cm }

or above
When a L-mode is not
Work equip- selected
F or R pump pressure is at 14.7 MPa {150 kg/cm2}
Travel single signal ment, swing,
or below
is ON
and service
singles are
or above
ON
When L mode is selected
or below
Travel signal is
OFF
Swing signal is OFF
2
Arm IN and bucket CURL F or R pump pressure is at 24.5 MPa {250 kg/cm }
or above
PPC pressure are
1.9 MPa {19.5 kg/cm2} or F or R pump pressure is at 19.6 MPa {200 kg/cm2}
above
or below
OFF
ON
OFF
ON
OFF
Table for functioning conditions Travel junction solenoid valve

Operation
Operating condition
Travel steering signal is ON
Travel steering signal is OFF
Travel lever is operated singly

or above
ON
OFF
Table for functioning conditions PPC lock solenoid valve

Operation
Operating condition
Work equipment lock lever
PC400, 450-7E0
Lock
OFF
Free
ON
45
SEN03597-01
Measuring PPC valve output

pressure
a
PPC valve output pressure measurement tools
Symbol
Q
1
2
Part No.
799-101-5002
Part name
Hydraulic tester
790-261-1204
799-301-1740
Joint (PF1/4 + PT1/4)

1.
Remove the control valve top cover and the

operator cab under cover (front side).
2.
Remove PPC hydraulic switch or PPC pressure sensors (1) to (10) of the target circuit of
measurement.
a PPC pressure sensor for arm IN and
bucket CURL detects errors in the electrical system as the starter switch is turned
on when the connector is disconnected.
After removing the pressure sensor, connect it to the connector again and then
clamp it to a nearby bracket.
No.
1
46
3.
Connect nipple [1] of joint Q2 and hydraulic

tester Q1 and connect them to oil pressure
gauge [2].
a Joint Q2 shall be used only when the measurement is taken at the pressure sensor
installation position.
a The oil pressure gauges used shall be 6
MPa {60 kg/cm2}.
a Figure shows the measuring tools being
installed at the installation position of PPC
pressure sensor for arm IN circuit.
4.

range.
Circuit to be meaCircuit to be meaNo.

sured
sured
Boom RAISE (S06)
Bucket DUMP (S05)
Boom LOWER (S02)
Swing LEFT (S07)
Arm IN (S04)
Swing RIGHT (S03)
Arm OUT (S08)
Travel (S30)
Bucket CURL (S01) 10 Steering (S31)
PC400, 450-7E0
5.
Measure the pressure when the engine is running at high idle and the control lever of the circuit to be measured is kept in the NEUTRAL
position and at the full stroke.
a If PPC valve output pressure is at the level
shown below, it is judged normal.
Operation of levers
Neutral
Stroke end
6.
SEN03597-01
Oil pressure
If there is excessive play in the work equipment or swing lever, adjust it in the following
manner.
1.
Remove the work equipment and swing PPC

valve assembly.
2.
Remove boot (1).
3.
Loosen locknut (2) and push disc (3) into piston (4) until it touches the heads of 4 pistons
(4).
a Do not move the piston while doing this
work.
4.
Keep disc (3) in place and tighten locknut (2) to

the specified tightening torque.
3 Locknut: 69 88 Nm {7 9 kgm}
5.
Install boot (1).
6.
Install the work equipment and swing PPC

valve assembly.
0 MPa {0 kg/cm2}
Almost the same pressure as the control circuit basic pressure (See
Standard values table)
PC400, 450-7E0
Adjusting play of work equipment

and swing PPC valves
1
47
SEN03597-01
Inspecting locations of hydraulic

drift of work equipment
2.
If hydraulic drift occurred on the work equipment (cylinder), check to see if the cause is on
the cylinder packing side or control valve side
1.
Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture as when measuring hydraulic drift,
and stop the engine.
a Fill the bucket with earth or apply the
rated load to the bucket.
Inspection of arm cylinder

1) Stop the arm cylinder at a position approximately 100 mm in front of the IN stroke
end and then stop the engine.
2)
2)
48
When inspecting the boom cylinder, shift

the boom control lever to RAISE side and
when inspecting the bucket cylinder, shift
the bucket control lever to CURL side.
q
If, as the result, drifting speed
increases, failure on the cylinder
packing should be suspected.
q
If the speed remains unchanged, failure on the control valve should be
suspected.
a Operate the control lever with the
engine starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx.
10 seconds to charge the accumulator again.
Operation the arm control lever in the IN

position
q
If the lowering speed is increased at
this time, the cylinder packing is
defective.
q
If the lowering speed does not
change at this time, the control valve
is defective.
a Operate the control lever with the engine
starting switch in the ON position.
dropped, run the engine for approx.
10 seconds to charge the accumulator again.
[Reference] Reasons why the lowering
speed is increased by the above operation
when the cylinder packing is the cause of
the hydraulic drift:
1) If the work equipment is set to the
above posture (holding pressure
applied to the bottom end), the oil at
the bottom end leaks to the head end.
However, the volume at the head end
is smaller than the volume at the bottom end by the volume of the rod end,
so the internal pressure at the head
end increases because of the oil flowing in from the bottom end.
2) If the internal pressure of the head
end increases, the pressure at the
bottom end also rises in proportion to
this and balanced at certain level (this
level depends on the volume of leakage). As the pressure is balanced, the
drifting speed is decreased.
PC400, 450-7E0
3)
3.
SEN03597-01
If the lever is then operated according

to the procedure given above, the circuit at the head end is opened to the
drain circuit (the bottom end is closed
by the check valve), so the oil at the
head end flows to the drain circuit and
the downward movement becomes
faster.
Inspection of PPC valve

Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the lock lever is put
to the LOCK and FREE positions.
a Operate the control lever with the engine
starting switch in the ON position.
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
a If the lock and free position cause any difference in the hydraulic drift volume, the
PPC valve is defective (internal failure).
PC400, 450-7E0
49
SEN03597-01
Releasing residual pressure from

hydraulic circuit
1
1.
2.
50
Releasing residual pressure from hydraulic tank

k Since the hydraulic tank is enclosed
and pressurized, release the residual
pressure from it when removing a hose
or a plug connected to it.
1) Lower the work equipment to the ground
in a stable position and stop the engine.
2) Loosen oil filler cap (1) of the hydraulic
tank gradually to release the air in the
tank.
3.
Releasing residual pressure from swing

motor circuit
a The residual pressure in the swing motor
circuit can be released by performing the
same operation for Releasing residual
pressure from hydraulic cylinder circuit
(Operate the lever in the swing direction
only, however).
4.
Releasing residual pressure from travel

motor circuit
a Since the control valve spool of the travel
motor circuit is open, the pressure in this
circuit can be released by performing the
same operation as that for Releasing
residual pressure from hydraulic tank.
Releasing residual pressure from hydraulic cylinder circuit

k When disconnecting a pipe between a
hydraulic cylinder and the control
valve, release the residual pressure
from the piping according to the following procedure.
1) Release residual pressure from the
hydraulic tank. For details, see Releasing
residual pressure from hydraulic tank.
a Keep the oil filler cap of the hydraulic
tank being removed.
2) Turn the starting switch ON and set the
lock lever in the FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the
right, and to the left.
a The control valve is operated by the
pressure stored in the accumulator.
This pressure in the accumulator,
however, is used up after the control
valve is operated 2 3 times.
3) Run the engine at low idle for 5 seconds to
increase the pressure in the accumulator.
a The engine does not start until the
lock lever is set in the LOCK position
once.
4) Repeat steps 2) and 3) above 2 3 times,
and the residual pressure in the piping is
released completely.
PC400, 450-7E0
SEN03597-01
Measuring oil leakage amount

a
Measuring tools for oil leakage
Symbol
Part No.
Commercially
available
1.
Part name
Measuring cylinder
3)
Measuring oil leakage from boom cylinder

operating range.
2) Move the boom cylinder to the RAISE
stroke end and stop the engine.
k Release the residual pressure from
the piping on the boom cylinder head
side. For details, see Releasing
residual pressure from hydraulic circuit. (Operate the lever in the boom
RAISE direction only, however).
3) Disconnect hose (1) on the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the
hose at the cylinder bottom end.
a Use the following parts to block the
hose side.
07379-01044 (Flange #10)
4)
5)
6)
3.
4)
5)
6)
2.
Run the engine at high idle and relieve the

boom circuit by raising the boom.
k Take care not to lower the boom.
Continue this condition for 30 seconds,
then measure the oil leakage amount for
one minute.
After the measurement, make sure that
the machine is back to normal condition.
Measurement of oil leakage amount from

arm cylinder
operating range.
2) Move the arm cylinder to the IN stroke end
PC400, 450-7E0
Release the residual pressure from

the piping on the arm cylinder
head side. For details, see Releasing residual pressure from hydraulic circuit (Operate the lever in the
arm IN direction only, however).
Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
hose side.
07379-01044 (Flange #10)

arm circuit by moving the arm IN.
k Take care not to move the arm OUT.
one minute.

bucket cylinder
operating range.
2) Move the bucket cylinder to the CURL
stroke end and stop the engine.
k Release the residual pressure from
the piping on the bucket cylinder head
side. For details, see Releasing
residual pressure from hydraulic circuit (Operate the lever in the bucket
CURL direction only, however).
3) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.
51
SEN03597-01
a

a
Use the following parts to block the

hose side.
07379-01044 (Flange #10)
5)
5.
4)
5)
6)
4.
4)
52

travel motor
1) Take off the travel motor cover.
2) Run the engine until the hydraulic oil is
heated up to the operating range and then
lock the travel lever to stop the engine.
k Insert pin [1] between the sprocket
and the track frame to positively
lock the travel circuit.

bucket circuit by curling the bucket.
k Take care not to Dump the
bucket.
one minute.

swing motor
operating range.
2) Disconnect drain hose (4) and block the
hose side with plugs.
hose side.
07376-70522 (Plug #05)
3)
Continue this condition for 30 seconds, then measure the oil leakage
amount for one minute.
a After measuring 1 time, swinging 180,
and then measure again.
3)
Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.
hose side.
07376-70522 (Plug #05)
Turn the swing lock switch to the ON position.

Run the engine at high idle, relieve the
swing circuit, and measure the oil leakage.
PC400, 450-7E0
4)
5)
SEN03597-01
Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signs and checks securely.
a Continue this condition for 30 seconds, then measure the oil leakage
amount for one minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
PC400, 450-7E0
53
SEN03597-01
Bleeding air from various parts
Air bleeding items
Air bleeding procedure

1
Bleeding air
from
hydraulic
pump
Starting
engine
Bleeding air Bleeding air Bleeding air

from cylin- from swing from travel
der
motor
motor
Checking oil
level and
starting
work
q
(See note)
q
(See note)
Replacing and repairing control

valve
Removing control valve piping
Replacing and repairing cylinder

Removing cylinder piping
Replacing and repairing swing

motor
Removing swing motor piping
Replacing and repairing travel

motor
Removing travel motor piping
Replacing and repairing swivel joint

Removing swivel joint piping
Contents of work
Replacing hydraulic oil
Cleaning strainer
Replacing return filter element
Replacing and repairing hydraulic
pump
Removing suction piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1.
54
Bleeding air from hydraulic pump

1) Loosen air bleeder (1) to make sure oil
oozes out through the air bleeder.
2) When oil does not flow out, disconnect
drain hose (2) and then fill up the pump
case with oil fed from the drain port.
a Fix the drain hose mouthpiece in a
position higher than the oil level in the
hydraulic tank.
a Continue supplying oil to the pump
case until air is eliminated from the
flowing out oil.
3) After making sure that the oil from bleeder
(1) is free from mixed air, tighten the
bleeder.
3 Air bleeder:
7.8 9.8 Nm {0.8 1.0 kgm}
a When the drain hose was disconnected for above operation, connect it
again after tightening the bleeder.
2.
Starting engine
When running the engine after performing step
1, keep its speed at low idle for 10 minutes.
a If the engine coolant temperature is low
and the automatic warm-up operation is
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the fuel
control dial in the MAX position for 3 seconds, and the automatic warm-up operation is reset).
PC400, 450-7E0
3.
Bleeding air from hydraulic cylinder

a In case a cylinder is replaced with new
one, it is advised to bleed air from the new
one before mounting the work equipment.
It is especially so with the boom cylinder,
because its rod does not extend to the
stroke end of LOWER side, after the work
equipment is mounted.
1) Start the engine and keep running at low
idle for 5 minutes.
2) Raise and lower the boom 4 to 5 times
with the engine running at low idle.
a Stop the piston approximately 100
mm in front of the stroke end so that it
may not be relieved.
3) While running the engine at high idle, perform step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end and
relieve the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) 4).
4.
Bleeding air from swing motor

1) Start the engine and run it at low idle.
2) Loosen S port hose (3) gradually to make
sure oil oozes out through the S port hose.
k In this case, don't try to turn on the
swing operation.
3) When oil does not flow out, stop the
engine once, disconnect S port hose and
then fill up the motor case with oil.
a As the motor case is filled up with oil,
connect S port hose once and then
repeat steps 1) and 2).
4) After making sure that the oil from S port
hose is free from mixed air, tighten the
hose.
5) Perform two times minimum of swing
operation in left and right directions at
slow speeds.
PC400, 450-7E0
SEN03597-01
5.
Bleeding air from travel motor

1) Take off the travel motor cover.
2) Start the engine and run it at low idle.
3) Loosen bleeder (4) to make sure oil oozes
out.
4) After making sure that the oil from bleeder
(4) is free from mixed air, tighten the
bleeder.
3 Air bleeder:
9.8 12.74 Nm {1.0 1.3 kgm}
5)
6)
Using the work equipment, lift the track

shoe of one side.
Gradually run the lifted track shoe at idle
for approximately two minutes.
a Repeat the same for the opposite
side track shoe.
55
SEN03597-01
6.
Checking oil level and refilling

1) Run the engine, retract the arm cylinder
and bucket cylinder to the stroke ends,
lower the work equipment to the ground,
2)
56
Check the oil level by sight gauge (5) on

the rear side of the hydraulic tank.
a The oil level is acceptable if it is situated between H and L lines.
a If the oil level is below line L, it is
insufficient. Add oil.
PC400, 450-7E0
PC400, 450-7E0
SEN03597-01
57
SEN03597-01

2008 KOMATSU
All Rights Reserved
58
SEN03598-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
2SHOP
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Special functions of machine monitor ............................................................................................................. 2
PC400, 450-7E0
SEN03598-00
Special functions of machine monitor
[1]: Figure input switch 1

[/]: Return switch

[E]: Upward move switch
[R]: Downward move switch
[3]: Input confirmation switch
PC400, 450-7E0
SEN03598-00
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically and others are displayed through the switch operations according to
the internal setting of the machine monitor.
q
Ordinary functions: Operator menu
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
q
Special functions: Service menu
The functions in this mode are not ordinarily displayed. Display and setting of these functions are available from the serviceman's operations of the special switches.
This mode is used for special setting, testing, adjusting or troubleshooting.
Operator menu
1 Password input and setting function
2 KOMATSU logo display screen
3 Check before starting function
Service menu
16 Monitoring [01] function
17
Function of abnormality record [02]
Electrical systems
Mechanical systems
4 Maintenance display function
18 Function of maintenance record [03]
5 Caution items display function
19 Function of maintenance mode change [04]
Check of working mode and travel speed function
20 Function of phone number entry [05]
7 Ordinary screen display function

Display's brightness and contrast adjusting func8
tion
E-mode adjustment and pump flow rate adjust9 ment function when breaker or attachment is
used
Mode with key ON

21
Language
Unit
With/Without attachment
10 Check of maintenance information function

11 Service meter display function
Function of default
[06]
22
Function of adjustment [07]
Pump absorption torque

Adjustment of flow to attachment in compound operation
12 Check of display LCD function
23 Function of cylinder cut-out operation [08]
13 Caution generation display function
24 Function of no injection cranking [09]
14 Action code display function

15 Failure code display function
PC400, 450-7E0
SEN03598-00
Operation of operator menu and display (outline)

a
This section introduces only the outline of the

operator menu. For details on the contents and
operation steps of each menu, refer to the
operation and maintenance manual or the
chapter of Structure, function and maintenance standard in this shop manual.
1.
Password input and setting function

Displays the password input screen as the
starting switch is turned ON.
a Above display is available only when the
password function is selected.
2.
3.
Check before starting function

Check before starting screen is displayed for 2
seconds succeeding to display of KOMATSU
logo.
4.
Maintenance display function

Succeeding to display of the check before
starting screen, a maintenance mark appears
for 30 seconds pointing the oil or filter whose
specified maintenance time has already
expired or going to expire soon.
a Above display is available only when the
maintenance function is selected.
KOMATSU logo display screen

KOMATSU logo is displayed for 2 seconds as
a password is entered (as a password is specified) or the starting switch is turned ON.
PC400, 450-7E0
5.
Caution items display function

Succeeding display of the check before starting scre en, an ap plica ble caution m ark
appears pointing a check before starting item
on which a problem was found.
6.
Check of working mode and travel speed

function
Succeeding to display of the check before
starting screen, symbol marks of the working
mode and travel speed appear sizably on the
screen to alert the operator attention to the setting.
PC400, 450-7E0
SEN03598-00
7.
Ordinary screen display function

The ordinary display is turned on succeeding
to display of the check of working mode and
travel speed screen.
a If the currently set working mode or travel
speed is changed or if setting of the autodeceleration or wiper is enabled from the
ordinary screen, an applicable symbol
mark is displayed large for 2 seconds.
a The engine pre-heating monitor is displayed only when the pre-heating operation is turned on.
8.
Display's brightness and contrast adjusting

function
The screen adjustment switches allow adjusting the display brightness and contrast.
SEN03598-00
9.
E-mode adjustment, flow rate adjustment

function when breaker or attachment is
used (for a machine equipped with breaker
and attachment)
The select switch allows adjusting E-mode and
also adjusting the pump flow rate when the
breaker or attachment is used.
a There are some differences between the
symbol mark of the breaker and attachment displayed on the screen as well as in
the messages displayed.
10. Check of maintenance information function

The maintenance switch allows checking
detailed information of the maintenance items
(specified maintenance time and elapsed
time). It also allows resetting after the maintenance.
a Setting and resetting of the maintenance
function as well as setting of the maintenance time is done from the service menu.
11. Service meter display function

Display of the service meter alone becomes
available by operating the following switches
after the starting switch is turned OFF.
q
Switch operation: [/] + [E]
(Simultaneous operation)
PC400, 450-7E0
12. Check of display LCD function

Display of the display LCD can check by operating the following switches from the password
input screen or ordinary screen.
q
Switch operation: [/] + [A] (Simultaneous
operation)
a The entire LCD should come on, turning
the screen to white. The display is, therefore, acceptable if it is free from any black
spot.
a Operating any switch from the checkup
display restores the immediately preceding screen.
PC400, 450-7E0
SEN03598-00
13. Caution generation display function

If a caution is warned for a caution item, applicable symbol mark is displayed large for 2 seconds and then it remains on the screen in a
smaller size until the trouble is eliminated.
SEN03598-00
14. Action code display function

If a trouble occurs on the machine, an applicable action code is automatically displayed
depending on the seriousness of the trouble in
order to alert the operator to take an appropriate action.
a Operating any switch while an action code
is on the screen, switch the failure code
display screen (see Item 15).
Action codes and actions requested to operator
Action code
Failure mode
Action
E02
Pump control system error
When emergency pump drive switch is at the up (emergency)

position, normal operations become possible, but have
inspection carried out immediately.
E03
Swing brake system error
Have inspection carried out immediately.
E10
Engine controller power source error

Engine controller drive system circuit
error
(engine stopped)
Have inspection carried out immediately.
E11
Engine controller system error

(Output reduced to protect engine)
Operate machine to a safe posture and have inspection carried out immediately.
E14
Throttle system error
E15
Engine sensor (coolant temperature, fuel

Operations are possible, but have inspection carried out
temperature and oil pressure) system
immediately.
error
E0E
Network error
PC400, 450-7E0
15. Failure code display function

Operating any switch while an action code is
on the screen, sequentially displays the phone
mark (if registered), phone number (if registered) and failure code.
q
Switching operation: (3) (keep the switch
depressed)
a The screen display sequentially changes
as shown below as long as the switch is
being depressed.
SEN03598-00
a
The telephone mark and telephone number are displayed only when the telephone
number is registered to the machine monitor.
Registration, correction or deletion of a
telephone number is done from the service menu.
For detailed information of failure codes,
see the failure codes table.
(1) Telephone symbol mark
(2) Telephone number
(3) Failure code
PC400, 450-7E0
SEN03598-00
Failure codes table

Action
code
Failure code
A000N1
10
Device in
charge
Category of record
Eng. Hi Out of Std
MON
Mechanical system
AA10NX
Aircleaner Clogging
MON
Mechanical system
AB00KE
Charge Voltage Low
MON
Mechanical system
B@BAZG
Eng. Oil Press. Low
MON
Mechanical system
B@BAZK
Eng. Oil Level Low
MON
Mechanical system
B@BCNS
Eng. Water Overheat
MON
Mechanical system
B@BCZK
Eng. Water Lvl Low
MON
Mechanical system
Trouble (Displayed on screen)
Alarm
buzzer
B@HANS
Hydr. Oil Overheat
MON
Mechanical system
E10
CA111
EMC Critical Internal Failure
ENG
Electrical system
E10
CA115
Eng Ne and Bkup Speed Sens Error
ENG
Electrical system
E11
CA122
Chg Air Press Sensor High Error
ENG
Electrical system
E11
CA123
Chg Air Press Sensor Low Error
ENG
Electrical system
E14
CA131
Throttle Sensor High Error
ENG
Electrical system
E14
CA132
Throttle Sensor Low Error
ENG
Electrical system
E15
CA135
Eng. Oil Press Sensor High Error
ENG
Electrical system
E15
CA141
Eng. Oil Press Sensor Low Error
ENG
Electrical system
E15
CA144
Coolant Temp Sens High Error
ENG
Electrical system
E15
CA145
Coolant Temp Sens Low Error
ENG
Electrical system
E15
CA153
Chg Air Temp Sensor High Error
ENG
Electrical system
E15
CA154
Chg Air Temp Sensor Low Error
ENG
Electrical system
E15
CA187
Sens Supply 2 Volt Low Error
ENG
Electrical system
E11
CA221
Ambient Press Sens High Error
ENG
Electrical system
E11
CA222
Ambient Press Sens Low Error
ENG
Electrical system
E15
CA227
Sens Supply 2 Volt High Error
ENG
Electrical system
CA234
Eng Overspeed
ENG
Mechanical system
E15
CA238
Ne Speed Sens Supply Volt Error
ENG
Electrical system
E15
CA263
Fuel Temp Sensor Hight Error
ENG
Electrical system
E15
CA265
Fuel Temp Sensor Low Error
ENG
Electrical system
E10
CA271
IMV/PCV1 Short Error
ENG
Electrical system
E10
CA272
IMV/PCV1 Open Error
ENG
Electrical system
E10
CA273
PCV2 Short Error
ENG
Electrical system
E10
CA274
PCV2 Open Error
ENG
Electrical system
E11
CA322
Inj #1 Open/Short Error
ENG
Electrical system
E11
CA323
ENG
Electrical system
E11
CA324
ENG
Electrical system
E11
CA325
ENG
Electrical system
E11
CA331
ENG
Electrical system
E11
CA332
ENG
Electrical system
E10
CA342
Calibration Code Incompatibility
ENG
Electrical system
E10
CA351
Injectors Drive Circuit Error
ENG
Electrical system
E15
CA352
ENG
Electrical system
E15
CA386
ENG
Electrical system
E10
CA441
Battery Voltage Low Error
ENG
Electrical system
PC400, 450-7E0
Action
code
Failure code
E10
CA442
E11
E11
SEN03598-00
Alarm
buzzer
Device in
charge
Category of record
Battery Voltage High Error
ENG
Electrical system
CA449
Rail Press Very High Error
ENG
Electrical system
CA451
Rail Press Sensor High Error
ENG
Electrical system
E11
CA452
Rail Press Sensor Low Error
ENG
Electrical system
E15
CA553
Rail Press High Error
ENG
Electrical system
E11
CA554
Rail Press Sensor In Range Error
ENG
Electrical system
E15
CA559
Rail Press Low Error
ENG
Electrical system
E15
CA689
Ne Speed Sensor Error
ENG
Electrical system
E15
CA731
Bkup Speed Sens Phase Error
ENG
Electrical system
E10
CA757
All Persistent Data Lost Error
ENG
Electrical system
E15
CA778
Bkup Speed Sensor Error
ENG
Electrical system
E15
CA1228
EGR Valve Servo Error 1
ENG
Electrical system
E15
CA1625
ENG
Electrical system
E0E
CA1633
KOMNET Datalink Timeout Error
ENG
Electrical system
E14
CA2185
Throt Sens Sup Volt High Error
ENG
Electrical system
E14
CA2186
Throt Sens Sup Volt Low Error
ENG
Electrical system
E11
CA2249
Rail Press Very Low Error
ENG
Electrical system
E11
CA2271
EGR Valve Pos Sens High Error
ENG
Electrical system
E11
CA2272
EGR Valve Pos Sens Low Error
ENG
Electrical system
E11
CA2351
EGR Valve Sol Current High Error
ENG
Electrical system
E11
CA2352
EGR Valve Sol Current Low Error
ENG
Electrical system
E15
CA2555
Grid Htr Relay Volt Low Error
ENG
Electrical system
E15
CA2556
Grid Htr Relay Volt High Error
ENG
Electrical system
D110KB
Battery Relay Drive S/C
PUMP
Electrical system
D196KA
Service Return Relay Disc.
PUMP
Electrical system
PUMP
Electrical system
PUMP
Electrical system
PUMP
Electrical system
D196KB
Service Return Relay S/C
E02
DA25KP
Press. Sensor Power Abnormality
DA80MA
Auto Lub Abnormal
E0E
DA2RMC
Pump Comm. Abnormality
PUMP
Electrical system
DA2SKQ
Model Selection Abnormality
PUMP
Electrical system
E0E
DAFRMC
Monitor Comm. Abnormality
PUMP
Electrical system
DHPAMA
F Pump P. Sensor Abnormality
PUMP
Electrical system
DHPBMA
R Pump P. Sensor Abnormality
PUMP
Electrical system
DHS3MA
Arm Curl PPC Sen. Abnormality
PUMP
Electrical system
DHS4MA
Bucket Curl PPC Sen. Abnormality
PUMP
Electrical system
DW43KA
Travel Speed Sol. Disc.
PUMP
Electrical system
DW43KB
Travel Speed Sol. S/C
PUMP
Electrical system
E03
DW45KA
Swing Brake Sol. Disc.
PUMP
Electrical system
E03
DW45KB
Swing Brake Sol. S/C
PUMP
Electrical system
DW91KA
Travel Junction Sol. Disc.
PUMP
Electrical system
DW91KB
Travel Junction Sol. S/C
PUMP
Electrical system
DWJ0KA
Merge-divider Sol. Disc
PUMP
Electrical system
DWJ0KB
Merge-divider Sol. S/C
PUMP
Electrical system
DWK0KA
2-stage Relief Sol. Disc.
PUMP
Electrical system
PC400, 450-7E0
11
SEN03598-00
Action
code
Failure code
DWK0KB
E02
E02
a
a
a
a
12
Device in
charge
Category of record
2-stage Relief Sol. S/C
PUMP
Electrical system
DXA0KA
PC-EPC Sol. Disc.
PUMP
Electrical system
DXA0KB
PC-EPC Sol. S/C
PUMP
Electrical system
DXE0KA
LS-EPC Sol. Disc.
PUMP
Electrical system
DXE0KB
LS-EPC Sol. S/C
PUMP
Electrical system
DXE4KA
Service Current EPC Disc.
PUMP
Electrical system
DXE4KB
Service Current EPC S/C
PUMP
Electrical system
DY20KA
Wiper Working Abnormality
MON
Electrical system
DY20MA
Wiper Parking Abnormality
MON
Electrical system
DY2CKB
Washer Drive S/C
MON
Electrical system
DY2DKB
Wiper Drive (For) S/C
MON
Electrical system
DY2EKB
Wiper Drive (Rev) S/C
MON
Electrical system
Alarm
buzzer
This table lists the failed sections in the order of the failure code.
Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
The category of record is used for indicating to which of the electrical and mechanical system of the service menu's abnormality record a given failure is classified.
E of at beginning the action code indicates the following state.
q
With E: The failure still remains without being resolved.
q
Without E: The failure is already resolved.
PC400, 450-7E0
Service menu operation and display
SEN03598-00
3)
Switching to service menu

a When using the service menu, switch the
screen through the following special operation.
1)
Displaying menu screen

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
Confirmation of display
Make sure that the conventional display is
turned on.
a Changing to Service Menu is usually available only from this conventional display.
Number
2)
Switch operation
Do the following switch operation.
q
Switch operation: [E] + [1] o [2] o [3]
(Enter the numbers while holding E down)
4)
PC400, 450-7E0
Service menu
00
Return (Ends the service menu)
01
Monitoring
02
Abnormality record
03
Maintenance record
04
Change of maintenance mode
05
Setting of telephone No.
06
Default
07
Adjustment
08
Cylinder cut out
09
No injection cranking
Ending the menu and function

When ending the operation from the service
menu screen or respective menu screens,
select either of the following operations.
q
Press [/] switch (enables every screen).
q
When RETURN switch is displayed,
press the applicable switch.
q
When Return menu is displayed, select
the menu and press [3] switch.
13
SEN03598-00

a
16. Monitoring [01] function

The machine monitor monitors signals from the
switch sensor actuators on various machine
parts. It allows displaying and checking the
monitored information through following operations.
1)
2)
Menu selection
Select 01 Monitoring in the initial display
of Service Menu and depress [3] switch.
3)
Operation for monitoring

As the monitoring information screen is
displayed, confirm the monitored information operating the machine.
4)
Monitored information holding function

You can hold every monitored information
by pressing [E] while monitoring is continued.
If you press [R] switch again in this condition, the currently held information will be
released.
Setting a monitoring item

Select and register an item to be monitored
through the following switch operation.
q
[E] switch: Selection
q
[R] switch: Selection
q
[3] switch: Registration
q
q
14
When you have registered all the

items that can be registered, the
screen will be automatically switched
to the monitoring information screen.
Monitored information are transmitted
via communication circuits.Thus the
number of selected items can impact
the communication speed. If truly real
time monitoring is required, reduce
the selected items to the minimum.
For details on the monitoring items,
display unit, etc., refer to the Table for
Monitoring Items.
A monitoring item can be set from 1 to

4 at maximum (Depending upon the
selected item, the max. number can
be less than four)
In case of monitoring 1 to 3 items,
move to the monitoring information
screen through any of the following
switch operations after the registration work has been completed.
[Hold down [3] switch (for about 3
seconds).
Select menu 99999 and press [3]
switch.
PC400, 450-7E0
5)
SEN03598-00
Machine setup mode switching function

If it becomes necessary to change settings of working mode, select mode, travel
speed and auto-decel while monitoring,
depress the corresponding switch, then
the mode confirmation display is shown.
a
a
Above figure shows the screen display in P-and E-mode (in B-mode,
part of the symbol mark shape is different from above).
After confirming the setting, press [3]
switch to return to the monitoring
screen.
If the setting was changed during
monitoring, the new setting is held
even after the operator menu is
restored from the service menu after
the monitoring is finished.
PC400, 450-7E0
15
SEN03598-00
List of Monitoring Items

Code
No.
Monitoring item
Unit (Default: ISO)

ISO
meter
inch
Remarks
00000
Return
(Not display)
End menu
99999
Display execution
(Not display)
Display execution
menu
00200
Controller Model Select
Numbers
00201
Machine ID
Numbers
01002
Engine Speed
r/min
rpm
01601
2nd Eng. Speed Command
r/min
rpm
01100
F Pump Pressure
MPa
01101
R Pump Pressure
MPa
07200
Arm IN PPC Pressure
MPa
07300
Bucket Curl PPC Pressure
rpm
rpm
kg/cm
psi
kg/cm
psi
kg/cm
psi
MPa
kg/cm
psi
04107
Coolant temperature
14200
Fuel temperature
04401
Hydr. Oil Temperature
01300
PC-EPC Sol. Curr.
mA
mA
mA
01500
LS-EPC Sol. Curr.
mA
mA
mA
01700
Service Sol. Curr.
mA
mA
mA
03200
Battery Voltage
03203
Battery Power Supply
04300
Battery Charge
01006
Engine Speed
r/min
rpm
rpm
37200
Engine oil pressure
MPa
kg/cm2
psi
36400
Common rail pressure
MPa
kg/cm2
psi
37400
Ambient Pressure
kPa
kg/cm2
psi
18400
Intake Temperature
18500
Charge Temperature
36500
Boost Pressure
kPa
18000
EGR Inlet Pressure-A
18100
EGR Valve Position
36700
Engine Torque Ratio
18700
Engine Output Torque
03000
04200
kg/cm
psi
kPa
kg/cm
psi
mm
mm
in
Nm
kgm
lbft
Fuel Dial Pos Sens Volt
Fuel Level Sensor Vol.
04105
Eng. Water Temp. Vol. Lo
04201
Fuel Temp. Sensor Vol.
04402
Hydr. Temp. Sensor Vol.
37201
Eng Oil Press Sens Volt
37401
Ambient Press Sens Volt
18401
Intake Temp Sens Volt
18501
Charge Temp Sens Volt
36501
Charge Press Sens Volt
36401
Rail Pressure Sens Volt
16
PC400, 450-7E0
Code
No.
SEN03598-00
Monitoring item
Unit (Default: ISO)

ISO
meter
inch
18101
EGR Valve Pos Sens Volt
17201
PCV Close Timing
CA
CA
CA
17500
Engine Power Mode
31701
Throttle Position
31706
Final Throttle Position
18600
Inject Fueling Command
36200
Rail Press Command
36300
37300
mm /st
mm /st
mm3/st
MPa
kg/cm2
psi
Injection Timing Command
CA
CA
CA
Fuel Rate
L/h
L/h
L/h
01602
2nd Eng. Speed Command
13113
Main Pump Absorb Torque
Nm
kgm
lbft
01900
01901
02300
02301
02200
02201
Pressure Switch 1
Pressure Switch 2
Solenoid Valve 1
Solenoid Valve 2
Switch Input 1
Switch Input 2
Swing
ON/OFF
Travel
ON/OFF
Boom Lower
ON/OFF
Boom Raise
ON/OFF
Arm Curl
ON/OFF
Arm Dump
ON/OFF
Bucket Curl
ON/OFF
Bucket Dump
ON/OFF
Service
ON/OFF
Travel Steering
ON/OFF
Travel Junction
ON/OFF
Swing Brake Sw.
ON/OFF
Merge-divider
ON/OFF
2-Stage Relief
ON/OFF
Travel Speed
ON/OFF
Service Return
ON/OFF
Lever Sw.
ON/OFF
Swing Release Sw.
ON/OFF
Swing Brake SW.
ON/OFF
Model Select 1
ON/OFF
Model Select 2
ON/OFF
Model Select 3
ON/OFF
Model Select 4
ON/OFF
Model Select 5
ON/OFF
Low Viscosity Fuel Mode
ON/OFF
02202
Switch Input 3
Key Switch (ACC)
ON/OFF
03700
Controller Output 1
Battery Relay Output
ON/OFF
Key Switch
ON/OFF
Start
ON/OFF
Preheat
ON/OFF
Light
ON/OFF
Rad. Level
ON/OFF
04500
Monitor Input 1
PC400, 450-7E0
Remarks
17
SEN03598-00
Code
No.
04501
04502
Monitoring item
Monitor Input 2
Monitor Input 3
Unit (Default: ISO)

ISO
meter
Aircleaner
ON/OFF
Eng. Oil Level
ON/OFF
Spare open
ON/OFF
Battery Charge
ON/OFF
Swing Brake Sw.
ON/OFF
Bzzr Cancel Sw.
ON/OFF
Window Limit Sw.
ON/OFF
W Limit Sw.
ON/OFF
P Limit Sw.
ON/OFF
inch
20216
ECM Build Version
20217
ECM CAL Data Ver
18900
ECM Internal Temp
20400
ECM Serial No
20200
Monitor Prog. Version
20212
Pump Con. Prog. Version
18
Remarks
PC400, 450-7E0
17. Function of abnormality record [02]

The monitor panel records and classifies the
past failure information as into the electrical
and mechanical failures. It allows displaying
and checking the information through the following operations.
1) Menu selection
Select 02 Abnormality Record in the initial display of Service Menu and depress
[3] switch.
2)
Number
Sub menu selection

Select the sub menu from the abnormality
record menu screen and then press [3]
switch.
SEN03598-00
3)
Contents of display of electrical system

abnormality record information screen
(1): Occurrence order of abnormalities
fro m latest one/Total num ber of
records
(2): Failure code (Equipment: 4 digits,
Phenomena: 2 digits)
(3): Elapsed time on service meter from
the first occurrence
(4): Contents of trouble
a See the operator menu Failure
codes table.
4)
Contents of display of mechanical system

abnormality record information screen
(1): Record number
(2): Contents of trouble
(3): Failure code (Equipment: 4 digits,
Phenomena: 2 digits)
(4): Total number of occurrences
(5): Service meter reading at first occurrence
a See the operator menu Failure
codes table.
Sub menu of abnormality record
00
Return (End of abnormality record)
01
Electrical systems
02
Mechanical systems
PC400, 450-7E0
19
SEN03598-00
5)
Resetting electrical systems

a Resetting abnormality record (deletion) is possible only with the electrical system. The abnormality record in
the mechanical system cannot be
reset.
a When resetting individual or all information in the abnormality record of
the electrical systems, implement the
18. Function of maintenance record [03]

The machine monitor records the maintenance
information of the filters, oils, etc., which the
operator can display and check by the following operations.
1) Menu selection
Select 03 Maintenance Record from the
initial display of Service Menu and then
depress [3] switch.
1]
Following switch operation from the

electrical system abnormality record
screen opens the reset screen.
q
Switch operation:
[E] + [1] o [2] o [3]
a Above is the same as that done
when switching to the service
menu.
2)
2]
20
Information to be displayed
q
Oil and filter names
q
Replacement time elapsed up to
present
q
Time elapsed on service meter up to
the last replacement
From the reset screen, do the switch

operation according to the screen
instructions.
a When a specific individual information alone is to be reset, be
sure to display the subject information on the screen using [E]
switch or [R] switch.
a When resetting all information,
the information to be displayed
on the screen can be any.
PC400, 450-7E0
19. Function of maintenance mode change [04]

Following procedure allows changing the currently set operating conditions of the maintenance display function.
q
Set function effective or ineffective
q
Change set replacement interval
1)
Menu selection
Select 04 Maintenance Mode Change
from the Service Menu and then depress
[3] switch.
SEN03598-00
Number
Items of the maintenance mode change
00
Return (End of change in the maintenance

mode)
01
Maintenance mode on/off
02
Engine oil change int.
03
Engine oil filter change int.
04
Fuel main filter change int.
41
Fuel pre filter change int.
06
Hyd oil filter change int.
07
Hyd tank breather change int.
08
Corrosion resistor change int.
09
Damper case service int.
10
Final drive case oil change int.
11
Machinery case oil change int.
12
Hydraulic oil change int.
13
Initialize all items
2)
Selection of item to be changed

Select the item to be changed from the
Maintenance Mode Change Selection
Menu screen.
PC400, 450-7E0
3)
01 and 12 menus are provided for

setting the whole maintenance mode,
while those from 02 through 11 are for
setting individual items.
Contents of Maintenance Mode On/Off

q
Use (On): The maintenance display
function of all oil and filter-related
items are turned effectual. (Irrespective of whether On or Off set for
individual items, this setting prevails)
q
Not use (Off): The maintenance display function of all oils and filterrelated items is disabled (precedence is given to this setting over the
On or Off selected for an individual
items).
21
SEN03598-00
4)
5)
Description of individual setting items

(1) Default value: The maintenance time
set in the monitor (recommended by
the manufacturer and cannot be
changed).
(2) Set value: Denotes the maintenance
time that can be freely set. The maintenance mode operates based on this
time (the time can be increased or
decreased in multiple of 50 hours by
use of [E] and [R] switches).
(3) Use (On): Maintenance display function for this item is enabled.
(4) Not use (Off): Maintenance display
function for this item is disabled.
a The lower limit of this setting is 50
hours.
Description of Initialize all items

Select this menu and then press [3]
switch to restore the default value for the
individually set information.
20. Function of phone number entry [05]

When the action code is displayed, following
procedure allows entering or correcting the
phone numbers to be displayed alternately
with the failure code.
a If a telephone number is not input, the
phone number screen is not displayed.
1)
22
2)
Changing the display

Select Entry next to change the display
to the Phone Number Entry display.
a Even if a Phone number is already
inputted, it is deleted if you switch the
Phone Number Entry screen.
3)
Entry and setting phone number

Following the method explained below,
enter a phone number in the Phone Number Entry display. (Entry automatically
begins with a cursor at the left end)
Menu selection
Select 05 Phone Number Entry menu
from the Service Menu initial screen and
then depress [3] switch.
PC400, 450-7E0
1]
2]
Using the numerical keypad, enter

the number starting with the cursor
position situated at the left end.
a Numbers can be entered up to
the max. 12 digits, bu t om it
unnecessary digits.
a When entered a wrong number,
depress [B] switch to return the
cursor by one digit.
Depress [3] switch when all the numbers have been entered.
a As the input is finished, the
screen changes to entry screen
shown above. If the entered
phone number is shown on this
display, the input is normal.
21. Function of default [06]

Following machine monitor- or machinerelated settings are modifiable. Do necessary
modifications as needed.
q
Working mode as starting switch is turned
ON
q
Language used in the service menu
q
Unit to be displayed in relation to the monitoring function
q
With/Without attachment
1)
Menu selection
Select 06 Default menu from the Service
Menu initial screen and then press [3]
switch.
SEN03598-00
2)
Selecting sub menu

Select the target sub menu of setting
change and then press [3] switch.
Number
Sub menu of default value
00
Return (End of default)
01
Mode to be selected as key is turned on
02
Language
03
Unit
04
Presence or absence of attachments
3)
Mode to be selected as key is turned on

Following operation allows specifying the
working mode to be displayed on the
machine monitor as the starting key is
turned ON.
PC400, 450-7E0
P-mode, E-mode, L-mode and Bmode: If any of above modes is specified, that mode will be constantly
turned ON as the starting switch is
pressed.
The mode that had been selected as
the starting key was turned off in the
last operation: This setting turns ON
the last used mode as the starting
switch is pressed.
23
SEN03598-00
4)
Default: This setting turns ON the

delivered default mode (P-mode) as
the starter switch is pressed.
If the engine is stopped from B-mode
on a machine equipped with the
attachment, this mode will be invariably selected as the starter switch is
turned ON the next time independent
of above setting.
6)
Function for selecting distinction of With/

Without Service Cir.
It is possible in this function to set a distinction between with or without attachment.
q
With Service Circuit: When an attachment is installed.
q
Without Service Circuit: When no
attachment is installed.
Language setting function

Service Menu allows switching the language between Japanese and English.
a
a
5)
24
The default language of the machine

monitor is English.
When using the machine monitor,
which is a spare part, in the Japanese-speaking sphere, switch this
function from English to Japanese.
When the attachment is installed, you

must select With Service Circuit
from this screen. Otherwise, the
selection function (the function for
sharing the attachment) won't be
available from the operator mode.
Unit selection function

You can select one from the three units to
be used in the monitoring function display
of Service Menu.
a SI unit system is the default setting of
the machine monitor.
PC400, 450-7E0
SEN03598-00
22. Function of adjustment [07]

The operator can adjust various items related
to the machine with the machine monitor.
1) Menu selection
Select 07 Adjustment menu from the
Service Menu initial screen and then
depress [3] switch.
2)
Sub menu selection

Select the sub menu on which setting
change is to be done and then press [3]
switch.
Adjustment
value
Torque
adjustment
value
Adjustment
value
Torque
adjustment
value
220
+4.0 kgm
225
1.0 kgm
221
+3.0 kgm
226
2.0 kgm
222
+2.0 kgm
227
3.0 kgm
223
+1.0 kgm
228
4.0 kgm
224
0.0 kgm
4)
Number
Adjustment of sub menu
00
Return (Ends the adjustment)
01
Pump absorption torque
02
Adjustment of flow to attachment in compound operation
3)
ATT flow rate adjustment function at compound operation

In the compound operation of attachments, you can adjust the flow rate allocation of the pump within the range shown in
the table below.
Function for Pump Absorption Torque

adjustment
The pump absorption torque can be
adjusted within the range shown in the
table below.
PC400, 450-7E0
Adjustment
value
Flow rate allocation to ATT
370
0.5 times
371
0.7 times
372
1.0 times
373
0.4 times
25
SEN03598-00
23. Function of cylinder cut out operation [08]

The operator can perform the engine on cylinder cut out operation with the machine monitor.
Cylinder Cut Out operation means to run the
engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to find out a
cylinder which does not output power normally
(combustion in it is abnormal).
1)
Selecting menu
Select 08 Cylinder cut out menu from the
service menu initial screen and press [3]
switch.
3)
2)
26
Resetting cut out cylinder

Press the switch corresponding to the disabled cylinder's number from switches [1]
to [6] of the machine monitor to be reset.
a If pressing the switch changes the
cylinder number on the screen to a
black letter enclosed in the black
frame, the cylinder is reset.
Selecting cylinder to be disabled

Press a switch corresponding to the cylinder No. to be disabled from switches [1] to
[6] of the machine monitor.
a If pressing the switch changes the
cylinder number on the screen to a
white letter enclosed in the white
frame, the cylinder is disabled (when
a wrong number is selected, press
the correct switch again).
a Number of cylinders to be reduced is
any.
PC400, 450-7E0
4)
Engine speed holding function

Pressing [E] switch while the engine
operation on cylinder cut out screen is
turned on holds the engine speed and its
speed is newly displayed in the lower
space.
Pressing [ R ] switch during holding cancels the holding function and deletes the
display in the lower space.
a If the holding function is used, the
held speed is displayed in the lower
space along with ( ) and the upper
space continuously displays the current speed.
a The holding function is usable independent of the currently set mode
the cylinder cut out or not.
PC400, 450-7E0
SEN03598-00
[Reference]: Using the holding function effectively

The engine speed being displayed on the screen
through the holding function remains on it until the
holding is cancelled. In other words, enabling or
disabling of the cylinder cut out mode does not
affect the display.
Thus, when identifying a failed cylinder quicker, following operation is effective.
(1): Run the engine from the normal operation
mode (no cylinder cut-out) and then hold the
speed of that time.
(2): Specify the cylinder to be diagnosed as the cut
out.
(3): Run the engine under the same condition as
that for (1). Then compare the engine speed at
that time and the held speed being displayed
to diagnose the cylinder.
(4): Reset a cut out cylinder independent of the
fluctuations in the engine speed.
(5): Repeat above steps (2) to (4) and then compare the results against that obtained from
other cylinders.
a If the diagnosis identified a cylinder on which
there was no decrease in the engine speed or
the decrease was small, it can be safely
judged that there must be some abnormalities
in its fuel.
27
SEN03598-00
24. Function of no injection cranking [09]

No injection cranking of the engine is available
from the machine monitor.
No injection cranking denotes stopping injection of fuel from the injector even if the engine
is run from the starting motor. This mode is
used, for instance, for measurement of compressive pressure.
a This setting must be done after stopping
the engine.
1)
2)
Selecting menu
Select 09 No Injection Cranking from the
service menu initial screen and press [3]
switch.
4)
Select No Injection and press [3] switch.

Under Preparation will be displayed on
the screen.
a The letters Under Preparation are
displayed in red.
5)
As the preparation for no injection cranking is completed, display of Under Preparation is replaced with After No
Injection.
a The letters After No Injection are
displayed in green.
From this state, crank the engine using
the starting motor.
a Limit the cranking time to 20 seconds
to protect the starting motor.
The initial screen for the no injection

cranking will appear.
a Check Communication will be displayed in red.
6)
3)
28
As the checkup is over, following screen

appears.
PC400, 450-7E0
7)
8)
SEN03598-00
After the no injection cranking is over,

press [3] switch from the previous screen
and the letters End will be displayed for 3
seconds.
a The letters End are displayed in
green.
Press Return when ending the no injection cranking.
If the no injection cranking function is

inadvertently selected while the
engine is running, Engine Running
will appear as No Injection in step 4)
is selected. This Engine Running
display remains on the screen even
after the engine is stopped. Restoring
the service menu screen alone
deletes the display.
PC400, 450-7E0
29
SEN03598-00

2008 KOMATSU
All Rights Reserved
30
SEN04149-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
2SHOP
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Procedure for turning on KOMTRAX terminal................................................................................................. 2
Indication by KOMTRAX terminal lamps......................................................................................................... 5
Handling voltage circuit of engine controller ................................................................................................... 8
Preparation work for troubleshooting of electrical system .............................................................................. 9
Procedure for testing diodes ......................................................................................................................... 14
Pm clinic service ........................................................................................................................................... 15
Undercarriage troubleshooting report ........................................................................................................... 22
PC400, 450-7E0
SEN04149-00
Procedure for turning on

KOMTRAX terminal
When the machine is delivered, KOMTRAX terminal is installed:

a When the machine is delivered, KOMTRAX
terminal is installed (machine with the standard
equipment), implement the following procedure.
1.
2.
Reporting of machine model, model number and serial number

Report the machine model, model number and
serial number to the person responsible to
operation of KOMTRAX.
Registration of KOMTRAX terminal
T he pers on res ponsi ble to oper ation of
KOMTRAX shall register the subject terminal
using the KOMTRAX client PC.
a See KOMTRAX administrator manual for
the procedure.
a Above completes the necessary operations.
When installing KOMTRAX terminal after the

machine is delivered:
a When installing KOMTRAX terminal after the
machine is delivered (machine with the retrospective equipment), implement the following
procedure.
1.
3)
4)
5)
6)
7)
8)
Disconnect the inspecting connector 1

and maintain that state for 5 seconds.
Turn ON the starting switch and maintain
that state for 5 seconds.
Disconnect the inspecting connector 2
Connect the inspecting connector 1 again
Connect the inspecting connector 2 again
Make sure that the KOMTRAX terminal 7segment indicator lamp is normally turned
on.
Station opening inspection

a Referencing Preparation work for troubleshooting of electrical system, confirm the
position of KOMTRAX terminal and the
inspecting connector (the inspecting conne c to r i s pr o v i de d a t t he b ot to m o f
KOMTRAX terminal).
a Finish the operations of steps 4) to 7)
within 30 seconds.
1) Turn OFF the starting switch and then,
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e
elapsed, proceed to the next step.
2) Make sure visually that the inspecting connectors 1 and 2 are connected.
q
Inspecting connector 1:
G02 (female) and G03 (male)
q
Inspecting connector 2:
G04 (female) and G05 (male)
PC400, 450-7E0

a
a
As [Normal] is indicated, proceed to

the next step.
If [Abnormal] is indicated, repeat the
procedure from step 1).
SEN04149-00
a
If [E: Network error] were displayed,

check the indication of [LED-C4] referencing KOMTRAX terminal lamp
indications. (When CAN is not recognized, check KOMTRAX terminal
CAN harness for troubles. If any,
repair the trouble and repeat the procedure from step 1)).
9)
Set the starting switch to START position

and maintain it in that state for 5 seconds.
Make sure the engine is not started.
a If the engine is started, repeat the
procedure from step 1).
10) Return the starting switch to ON position
a Don't return it to OFF position.
11) Set the starting switch to START position
ag a i n a n d m a k e s ur e t h e e n gi n e is
started.
12) Make sure that the KOMTRAX terminal 7 segment indicator lamps are normally
turned on.
a As [A: Normal] is confirmed, proceed
to the next step (it will take 90 seconds to 15 minutes until normal display is restored).
a If [B: GPS position data sensing error]
we re di s pla yed , c hec k th e G P S
antenna and cable for external troubles. If any, repair the trouble and
repeat the procedure from step 1).
a If [C: Receiving error] were displayed,
check the communication antenna
and cable for external troubles. If any,
repair the trouble and repeat the procedure from step 1).
a If [D: GPS position data sensing error
and receiving error] were displayed,
check the GPS antenna and cable as
well as the communication antenna
and cable for external troubles. If any,
repair the trouble and repeat the procedure from step 1).
PC400, 450-7E0
SEN04149-00
13) Turn the starting switch OFF.

14) Make sure that the 7-segment indicator
lamp comes on normally in 5 seconds.
a As [Normal] is displayed, the station
opening inspection is complete.
a If [Abnormal] is displayed, the inspection is incomplete and must be
repeated from step 1).
2.
Application for start of use

a The application for start of use is allowed
only after the terminal station opening
inspection has been successfully ended.
1) Concerning the machine for which the station opening inspection has been completed, report the following information to
the person responsible to operation of
KOMTRAX.
(1) Information of the machine for which
the station opening inspection has
been completed (machine model,
model number and serial number)
(2) Part number and serial number of
KOMTRAX terminal
(3) The service meter reading when
KOMTRAX terminal was installed (in
0.1 h unit)
2)
The person responsible to operation of

KOMTRAX shall register the machine
using the KOMTRAX client PC.
a See KOMTRAX administrator manual for the procedure.
a Above completes the necessary operations.
PC400, 450-7E0
SEN04149-00
Indication by KOMTRAX terminal lamps
LEDs for CPU

1. LED-C1 (R signal and ACC signal)
2. LED-C2 (Condition of starting output)
3. LED-C3 (Condition of S-NET and C signal)
4. LED-C4 (Condition of CAN)
5. LED-C5 (Download writing condition)
6. LED-C6 (Download writing condition)
PC400, 450-7E0
7-segment lamp and dot for CPU

7. 7-segment lamp (Number of mails which are
not sent yet)
8. Dot (Measuring condition of GPS)
SEN04149-00
The KOMTRAX system indicates the information in the system and contents of processing with the LED display unit at the top of the KOMTRAX terminal. Accordingly, if the system seems to have a trouble, carry out
the following checks.
q
Check of antennas
q
Check of terminal LEDs
Before using the KOMTRAX system, you must complete application for start of use and inspection of the
machine for starting use.
Check of antennas
a Before checking the indication of the LED unit, check that the communication antenna and GPS
antenna are free from abnormality.
q
The communication antenna must not be off the position and must not be broken.
q
The communication antenna cable must not be disconnected and must be connected to the KOMTRAX
terminal normally.
q
The GPS antenna must not be off the position and must not be broken.
q
The GPS antenna cable must not be disconnected and must be connected to the KOMTRAX terminal
normally.
Check of terminal LEDs
1. Contents of indication of LEDs for CPU
a When checking the indication of the LEDs, turn the starting switch to the ON or START position or run
the engine.
No.
LED
Name/Function
Starting switch ACC

LED-C1 signal and alternator
R signal
Condition of engine
control signal
LED-C2
Condition of S-NET
LED-C3 connection and starting switch C signal
LED-C4
Condition of CAN
connection
Indication (*1)
ON
Starting switch ACC signal: ON, Alternator R signal: ON
Quick blink
Starting switch ACC signal: OFF, Alternator R signal: ON
Slow blink
Starting switch ACC signal: ON, Alternator R signal: OFF
OFF
Starting switch ACC signal: OFF, Alternator R signal: OFF
ON
Engine control signal: ON
OFF
Engine control signal: OFF
ON
S-NET: Connected, Starting switch C signal: OFF
Quick blink
Starting switch C signal: ON
Slow blink
(Unused)
OFF
S-NET: Disconnected, Starting switch C signal: OFF
ON
CAN: Installed, (Fuel sensor: Not installed)
Quick blink
CAN: Installed, (Fuel sensor: Installed)
Slow blink
CAN: Not installed, (Fuel sensor: Installed)
OFF
5
6
LED-C5 Condition of
download writing
LED-C6
Contents of indication
Either is ON
CAN: Not installed, (Fuel sensor: Not installed)

Download writing mode (Special function of system
administrator)
Both are OFF Normal operation mode
*1: Types of blink and blinking interval

Quick blink: Blinking at intervals of about 1 second
Slow blink: Blinking at intervals of about 4 seconds
PC400, 450-7E0
2.
a
Contents of indication of 7-segment lamp and dot for CPU

When checking the indication of the LEDs, turn the starting switch to the ON position.
No. Indicator
SEN04149-00
7-segment
lamp
Dot
Name/Function
Indication (*2)
Lighting of 0 9
Number of mails
which are not sent yet
and satellite capturQuick blink of
ing condition
09
Measuring condition
of GPS
Contents of indication
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Lighting indicates that satellite is captured.
Figure indicates number of mails which are not sent yet (When
10 or more mails are not sent yet, 9 is indicated).
Quick blink indicates that satellite is not captured.
ON
GPS has completed measuring (Position is recognized. See

*3.)
OFF
GPS has not completed measuring (Position is not recognized.

See *3.)
*2: Types of blink and blinking interval

Quick blink: Blinking at intervals of about 1.0 seconds
Slow blink: Blinking at intervals of about 4.0 seconds
*3: Remarks on measuring condition of GPS
Even in an outdoor place where the radio waves are strong enough, it may take more than 1 minute to
complete measurement after the starting switch is turned ON. If the radio waves are very weak or no
radio waves are received, the GPS cannot measure the position.
PC400, 450-7E0
SEN04149-00
Handling voltage circuit of engine

controller
1
1.
Before disconnecting or connecting a connector between the engine controller and engine,
be sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
PC400, 450-7E0
SEN04149-00
Preparation work for

troubleshooting of electrical
system
2.
When troubleshooting the

e n g i n e c o n t r o l l e r, p u m p
KOMTRAX terminal-related
bare applicable connectors
1.
Machine monitor
1) Take off cover (1).
a The cover is fixed with two upper and
lower clips. Pull it up for the removal.
If the sunlight sensor is equipped for
an air conditioner, disconnect P15
connector at the cover rear side.
Engine controller
1) Open the engine hood cover on the control valve side.
2) Remove cover (1).
monitor panel,
controller and
electrical circuit,
according to the
3)
2)
3)
Insert or connect troubleshooting T-adapters in or to connectors ENG, CE02, and

CE03 of engine controller (2).
a Connectors are fixed with screw.
Loosen the screws before disconnecting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
Remove the 3 mounting screws to disconnect machine monitor (2) from the mount.
a Use care so that the screws may not
fall into the console.
Insert or connect troubleshooting Tadapter for troubleshooting to connectors
P01, P02 and P70 of machine monitor.
PC400, 450-7E0
SEN04149-00
3.
Pump controller
a The engine throttle and pump controller
are installed in the cover situated in the
rear side of the operator seat.
1) Remove the 3 mounting bolts and cover
(5).
2)
10
Insert or connect troubleshooting T-adapter

in or to connectors CP01, CP02 and CP03
of pump controller (6).
a Connectors are fixed with screw.
a When returned the connectors to their
original positions, fix them by tightening the screws with the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
4.
KOMTRAX terminal
a KOMTRAX terminal is installed in the
cover situated in the rear side of the operator seat.
1) Remove the 3 mounting bolts and cover
(5).
2)
Insert or connect troubleshooting T-adapter

in or to connector G01 KOMTRAX of terminal (7).
a The connectors are fixed with screw.
a When returning the connectors to
their original positions, fix them by
tightening the screws with the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
a Cable (8) is for the communication
antenna.
a When cable (8) is currently disconnected, be sure to connect it again at
this stage to the connector situated
outside of the terminal.
Care must be exercised in this operation since connecting the cable to the
opposite connector disables the communication.
a Cable (9) is used for the GPS
antenna.
PC400, 450-7E0
5.
Atmospheric pressure sensor (AMBAIR

PRESSURE)
Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of connectors
The connectors of the atmospheric pressure sensor, engine Ne speed sensor,
engine Bkup speed sensor, engine oil
pressure switch have a special locking
mechanism. Disconnect them according
to steps (a) (c) and connect them
according to steps (d) (f) as shown
below.
Disconnection: (a) Slide lever (b)
Unlock (c) Disconnect connector.
Connection: (d) Connect connector (e)
Lock (f) Slide lever.
SEN04149-00
6.
Boost pressure and temperature sensor

(BOOST PRESS & IMT)
a Disconnection and connection of connector
The connector of the boost pressure and
temperature sensor has a special locking
mechanism. Disconnect it according to
steps (a) (b) and connect it according to
steps (c) (d) as shown below.
Disconnection: (a) Unlock (b) Disconnect connector.
Connection: (c) Connect connector (d)
Lock.
7.
Removal and installation of sensor
A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See "Tools for testing, adjusting,
and troubleshooting".
PC400, 450-7E0

A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See "Tools for testing, adjusting, and troubleshooting".
Supply pump IMV solenoid (FUEL REGULATOR)

The connector of the supply pump IMV
solenoid has a special locking mechanism. Disconnect it according to steps (a)
(b) and connect it according to steps (c)
(d) as shown below.
Lock.
11
SEN04149-00
12
Precautions for disconnecting connector

The direction of the lock of the connector
varies with the tightened position of the
sensor and the lock may be in a direction
in which it is difficult to reset (on the underside or engine side).
In this case, pinch the lock in direction (a)
with bent-nose nippers [1] (commercially
available), and the lock is reset.
Since the lock clicks when it is reset, disconnect the connector after a click is heard.
Precautions for connecting connector

Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness side
with triangular notch (f) on the sensor side
(Do not engage lock (e) with square guide
(g) on the opposite side of triangular notch
(f)).
8.
Common rail pressure sensor (FUEL RAIL

PRESS)
The connector of the common rail pressure sensor has a special locking mechanism. Disconnect it according to steps (a)
(b) and connect it according to steps (c)
(d) as shown below.
Lock.
PC400, 450-7E0
9.
SEN04149-00
Engine coolant temperature sensor (COOLANT TEMP)

The connector of the engine coolant temperature sensor has a special locking
mechanism. Disconnect it according to
steps (a) (b) and connect it according to
steps (c) (d) as shown below.
Lock.

A deep socket is necessary for removal
and installation of the engine coolant temperature sensor. See "Tools for testing,
adjusting, and troubleshooting".
PC400, 450-7E0
13
SEN04149-00
Procedure for testing diodes

a
a
Test the assembled-type diode (8-pin) and the

single diode (2-pin) according to the following
procedure.
The conductive directions of the assembledtype diode are as follows.
2.
The conductive direction of the single diode is

indicated on the surface of the diode.
1.
When using digital circuit tester

1) Set the tester in the diode range and
check the indicated value.
a When an ordinary circuit tester is
used, the voltage of the internal battery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black () lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q
The indicated value does not change:
The diode does not have conductivity
(Defective).
q
The indicated value changes:
The diode has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indicated.
14
When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
apply the black () lead to the cathode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black () lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
q
The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
q
The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
q
The pointer moves in neither of i) and
ii): The diode is defective (Internal
disconnection).
PC400, 450-7E0
SEN04149-00
Pm clinic service
Machine model
T PC400-7E0
T PC450-7E0
Model number
Service meter
h
T LC
User name
Date of execution
/
Inspector
Specifications
Main components
Boom T
Arm
T
Bucket T
Standard T (
Standard T (
Standard T (
Attachments
) T Breaker
) T(
) T(
Shoe width
T 600 mm
T 700 mm
T(
)
)
T 800 mm
)
Check of oil/coolant level

T Radiator coolant
T Engine oil
T Hydraulic oil
When necessary
T Damper case oil
T Final drive case oil
T Machinery case oil

T(
)
Ambient temperature
Altitude
C
m
Operator's opinion
Result of visual inspection
Mechanical systems abnormality record
Electrical systems abnormality record
A000N1
Times/1st time
h/Latest
Times/1st time
h/Latest
AA10NX
Times/1st time
h/Latest
Times/1st time
h/Latest
AB00KE
Times/1st time
h/Latest
Times/1st time
h/Latest
B@BAZG
Times/1st time
h/Latest
Times/1st time
h/Latest
B@BAZK
Times/1st time
h/Latest
Times/1st time
h/Latest
B@BCNS
Times/1st time
h/Latest
Times/1st time
h/Latest
B@BCZK
Times/1st time
h/Latest
Times/1st time
h/Latest
B@HANS
Times/1st time
h/Latest
Times/1st time
h/Latest
Max. range of engine coolant temperature

gauge
PC400, 450-7E0
Max. range of hydraulic oil temperature gauge
15
SEN04149-00
Items related to engine
16
PC400, 450-7E0
SEN04149-00
Items related to oil pressure
PC400, 450-7E0
17
SEN04149-00
Check sheet (PC400/450-7E0)

Model
Serial No.
Service meter
User's name
Date of execution
/
Engine speed
Engine oil
pressure
Engine speed
Engine oil
pressure
Engine speed
Blow-by
pressure
Engine oil
pressure
Work- AutoLeft knob

ing
decelswitch
mode eration
Operation of
work
equipment
All levers in
neutral
MAX
OFF
MIN
All levers in
neutral
OFF
P
Unit
Standard
value for new
machine
rpm
1,880 1,980 1,880 1,980
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
rpm
975 1,025
975 1,025
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
rpm
ON
Arm IN relief
OFF
All levers in
neutral
MAX
ON
rpm
1
2
Max. 1.76
{Max. 180}
Check item
Fuel Workcontrol ing

dial
mode
1,200 1,400 1,200 1,400
No load, work equipment

extended fully
Boom RAISE
P
Arm IN
Arm OUT
MAX
Bucket CURL
Swing (5 turns)
3.6 4.4
Max. 4.8
PC450-7E0
3.8 4.6
Max. 5.0
PC400-7E0
3.2 4.0
Max. 4.3
PC450-7E0
3.2 4.0
Max. 4.3
PC400-7E0
3.9 4.7
Max. 5.0
PC450-7E0
4.2 5.2
Max. 5.4
PC400-7E0
3.9 4.7
Max. 5.0
PC450-7E0
4.2 5.2
Max. 5.4
PC400-7E0
4.7 5.7
Max. 6.0
sec
5.1 6.1
Max. 6.3
Boom and arm top horizontal PC400-7E0

Arm cylinder retracted fully PC450-7E0
3.2 4.0
Max. 4.3
3.2 4.0
Max. 4.3
Work equipment extended fully
29.7 36.3
Max. 38
LO
One side of track pushed up
MI
HI
18
Standard
Service limit
value for
value
new machine
PC400-7E0
PC450-7E0
P
Travel (5 turns)
Unit
Checking posture, etc.
Boom top horizontal
2.94
{300}
3
4
Measured
value
1,730 1,930 1,730 1,930
kPa
{mmH2O}
Checking condition
No.
Service limit
value
STD
50.6 75.8
42.0 80.0
LC
53.8 80.8
45.0 84.5
STD
38.3 51.9
31.5 55.0
LC
40.9 55.3
34.0 58.0
STD
31.0 38.0
28.0 41.5
LC
33.1 40.3
32.0 44.0
Measured
value
Bad
2.
Fuel
control
dial
Bad
Check item
Good
Engine
Checking condition
No.
Good
1.
Inspector
PC400, 450-7E0
4.
Check item
Working
mode
Unit
Checking posture, etc.
Boom top horizontal

PC400-7E0 mm/
Hydraulic drift of
Engine stopped Arm cylinder retracted fully
bucket tip
PC450-7E0 15 min
Bucket loaded
Checked part
Self pressure
reducing valve
Main relief valve

(Low pressure)
Main relief valve

(Low pressure)
Unload valve
Fuel
control
dial
WorkLeft knob
ing
switch
mode
Max. 900
Max. 700
Max. 1,050
[2]
[3]
[4]
[5]
600K
600K
600K
600K
60K
Operation of work
equipment
F pump
main
R pump
main
F pump
LS
R pump
LS
Control
All lever in neutral
Arm out relief

ON
All levers in neutral
D1
D1
D2
D2
Right track driven idle E1

Lever moved halfway
LS valve
Left track driven idle

Lever moved halfway
Swing motor
safety valve
OFF
Main relief valve

Travel motor
Safety valve
Travel junction
valve
Checked oil pressure
Unit
A (Control circuit basic pressure)

Standard value
Max. 600
Measured
value
[1]
OFF
MAX
6
Service limit
value
Hydraulic circuit
Checking condition
No.
Standard
value for
new
machine
Bad
No.
Fuel
control
dial
Good
Checking condition
Bad
Good
3.
SEN04149-00
B (Work equipment relief pressure,

low)
C (Work equipment relief pressure,
high)
D (Unload pressure)
MPa
{kg/cm2}
E1
Swing lock
Right swing relief
Swing lock
Left swing relief
E2
E2
Right travel lock G

Right forward relief
Right travel lock G

Right reverse relief
Left travel lock

Left forward relief
Left travel lock

Left reverse relief
G
G
Standard value for new machine
Service limit value
3.04 3.44 {31 35}
2.84 3.43 {29 35}
33.83 36.28 {345 370}
33.34 36.77 {340 375}
36.29 38.74 {370 395}
35.79 39.23 {365 400}
3.2 5.2 {43 53}
3.2 5.2 {43 53}
2.55 2.75 {26 28}
2.55 2.75 {26 28}
F (Swing relief pressure)
28.44 32.36 {300 340}
27.95 32.85 {285 335}
G (Travel relief pressure)
36.29 40.21 {370 410}
35.79 40.7 {365 415}
E (LS differential pressure)
PC400, 450-7E0
19
SEN04149-00
Servo piston
Fuel
control
dial
WorkLeft knob
ing
switch
mode
MAX
OFF
Unit
H (Servo control pressure)
Operation of work
equipment
Arm out relief
[3a]
[4a]
[5]
600K
600K
600K
600K
60K
F pump
main
R pump
main
F pump
servo
R pump
servo
Control
H1
H1
H2
H2
Bad
Standard value
Check item
[2]
Bad
No.
[1]
Good
Checking condition
Good
* Gauge changing work: Change hoses of gauges [3] and [4].
Service limit value
H1 : H2 = 1 : 0.6
(Oil pressure ratio)
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1]
[2]
[3b]
[4b]
[5a]
600K
600K
60K
60K
60K
F pump
main
R pump
main
F pump
(F)
R pump
(R)
LS-EPC
J1
J1
J2
J2
J3
J3
J4
J4
J5
J5
Travel speed: Lo
travel lever in neutral
Travel speed: Mi
Travel lever operated
Travel speed: Hi
Travel lever operated
Checking condition
No.
Check item
Fuel
control
dial
WorkLeft knob
ing
switch
mode
Operation of work
equipment
MIN
P
PC-EPC (F)
valve
PC-EPC (R)
valve
L
B
OFF
MAX
10
LS-EPC valve
Standard value
20
Unit
K1
Service limit value
J2 (PC-EPC valve output pressure 2)
Approx. 0.4 {Approx. 4}

MPa
{kg/cm2}
K3
K2

K1 (LS-EPC valve output pressure 1)
0 {0}
PC400, 450-7E0
SEN04149-00
Visual check of welded structure

a If a crack is found, illustrate its shape in the drawing.
Arm
1. Arm cylinder bracket
T Left
T Right
2. Arm foot
T Left
T Right
T Edge plate
3. Arm top boss
T Left
T Right
PC400, 450-7E0
Boom
4. Arm top bracket
T Left
T Right
5. Boom cylinder bracket
T Left
T Right
6. Arm cylinder bracket
T Left
T Right
7. Boom lower plate
T Left
T Right
8. Boom foot
T Left
T Right
Revolving frame
9. Boom bracket
T Left
T Right
Track frame
10. Circle bracket
T Front
T Rear
T Left
T Right
21
SEN04149-00
Undercarriage troubleshooting report
1
(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
T20606
Customer name:
Address:
PC400/450-7E0
Model
Location
Soil condition
Working condition
Serial#
Equip#
Work Order No
SMR
Wet,AR,HD or Dry
Dealer
Shoe width (mm)

Shoe type
nspector
LH
Insp.Date(yyyy/mm/dd)
New 100% Measured
Wear
mm
915.6 927.6
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
DRY
TRIPLE
Wear type
NORMAL
Comments/Observation
R
RH
915.6
LH
228.90 231.90
927.6
RH
228.90 231.90
LH
129.0
119.0
RH
129.0
119.0
LH
71.5
66.5
RH
71.5
66.5
LH
37.0
22.0
RH
37.0
22.0
LH
148.0
134.0
RH
148.0
134.0
LH
148.0
134.0
RH
148.0
134.0
LH
22.0
28.0
RH
22.0
28.0
LH
22.0
28.0
New
Turned
New
Turned
Front
Rear
Front
Rear
1.3
RH
22.0
28.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
LH
200.0
188.0
10
LH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
RH
200.0
188.0
10
RH
200.0
188.0
LH
0.0
6.0
RH
0.0
6.0
Remarks:
22
PC400, 450-7E0
PC400, 450-7E0
SEN04149-00
23
SEN04149-00

2008 KOMATSU
All Rights Reserved
24
SEN04150-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting

Failure codes table.......................................................................................................................................... 2
Before carrying out troubleshooting when failure code is displayed ............................................................... 6
PC400, 450-7E0
SEN04150-00
40 Troubleshooting
Failure codes table

Action
Failure code
code
1
Device in
charge
Category of record
A000N1
Eng. Hi Out of Std
MON
Mechanical system
AA10NX
Aircleaner Clogging
MON
Mechanical system
AB00KE
Charge Voltage Low
MON
Mechanical system
B@BAZG
Eng. Oil Press. Low
MON
Mechanical system
B@BAZK
Eng. Oil Level Low
MON
Mechanical system
B@BCNS
Eng. Water Overheat
MON
Mechanical system
B@BCZK
Eng. Water Lvl Low
MON
Mechanical system
B@HANS
Hydr. Oil Overheat
MON
Mechanical system
E11
CA111
EMC Critical Internal Failure
ENG
Electrical system
E11
CA115
ENG
Electrical system
E11
CA122
ENG
Electrical system
E11
CA123
ENG
Electrical system
E14
CA131
ENG
Electrical system
E14
CA132
ENG
Electrical system
E15
CA135
Eng. Oil Press Sensor High Error
ENG
Electrical system
E15
CA141
Eng. Oil Press Sensor Low Error
ENG
Electrical system
E15
CA144
ENG
Electrical system
E15
CA145
ENG
Electrical system
E15
CA153
ENG
Electrical system
E15
CA154
ENG
Electrical system
E15
CA187
ENG
Electrical system
E15
CA221
ENG
Electrical system
E15
CA222
ENG
Electrical system
E15
CA227
ENG
Electrical system
CA234
Eng Overspeed
ENG
Mechanical system
E15
CA238
ENG
Electrical system
E15
CA263
Fuel Temp Sensor Hight Error
ENG
Electrical system
E15
CA265
ENG
Electrical system
E11
CA271
ENG
Electrical system
E11
CA272
IMV/PCV1 Open Error
ENG
Electrical system
E11
CA273
PCV2 Short Error
ENG
Electrical system
E11
CA274
PCV2 Open Error
ENG
Electrical system
E11
CA322
Inj #1 (L#1) Open/Short Error
ENG
Electrical system
E11
CA323
ENG
Electrical system
E11
CA324
ENG
Electrical system
E11
CA325
ENG
Electrical system
E11
CA331
ENG
Electrical system
E11
CA332
ENG
Electrical system
E10
CA342
ENG
Electrical system
E10
CA351
ENG
Electrical system
E15
CA352
ENG
Electrical system
E15
CA386
ENG
Electrical system
E10
CA441
ENG
Electrical system
Reference
document No.
Troubleshooting
by failure code
(Display of code),
Part 1
SEN03601-00
Troubleshooting
by failure code
(Display of code),
Part 2
SEN03602-00
PC400, 450-7E0
40 Troubleshooting
Action
Failure code
code
SEN04150-00
Device in
charge
Category of record
ENG
Electrical system
E10
CA442
E11
CA449
ENG
Electrical system
E11
CA451
ENG
Electrical system
E11
CA452
ENG
Electrical system
E15
CA553
ENG
Electrical system
CA554
ENG
Electrical system
E15
CA559
ENG
Electrical system
E11
CA689
Ne Speed Sensor Error
ENG
Electrical system
E11
CA731
Bkup Speed Sens Phase Error
ENG
Electrical system
E10
CA757
ENG
Electrical system
E11
CA778
Bkup Speed Sensor Error
ENG
Electrical system
E15
CA1228
ENG
Electrical system
E15
CA1625
ENG
Electrical system
E0E
CA1633
ENG
Electrical system
E14
CA2185
ENG
Electrical system
E14
CA2186
ENG
Electrical system
E11
CA2249
ENG
Electrical system
E11
CA2271
EGR Valve Pos Sens High Error
ENG
Electrical system
E11
CA2272
EGR Valve Pos Sens Low Error
ENG
Electrical system
E11
CA2351
ENG
Electrical system
E11
CA2352
ENG
Electrical system
E15
CA2555
ENG
Electrical system
E15
CA2556
ENG
Electrical system
D110KB
PUMP
Electrical system
D196KA
PUMP
Electrical system
D196KB
PUMP
Electrical system
E02
DA25KP
5V sensor power supply output 1 abnormality
PUMP
Electrical system
E0E
DA2RMC
PUMP
Electrical system
DA2SKQ
PUMP
Electrical system
E0E
DAFRMC
PUMP
Electrical system
DHPAMA
PUMP
Electrical system
DHPBMA
PUMP
Electrical system
DHS3MA
PUMP
Electrical system
DHS4MA
PUMP
Electrical system
DW43KA
PUMP
Electrical system
DW43KB
PUMP
Electrical system
E03
DW45KA
PUMP
Electrical system
E03
DW45KB
PUMP
Electrical system
DW91KA
PUMP
Electrical system
DW91KB
PUMP
Electrical system
DWJ0KA
Merge-divider Sol. Disc
PUMP
Electrical system
DWJ0KB
Merge-divider Sol. S/C
PUMP
Electrical system
DWK0KA
PUMP
Electrical system
DWK0KB
PUMP
Electrical system
PC400, 450-7E0
Reference
document No.
Troubleshooting
by failure code
(Display of code),
Part 2
SEN03602-00
Troubleshooting
by failure code
(Display of code),
Part 3
SEN03603-00
SEN04150-00
Action
Failure code
code
40 Troubleshooting
Device in
charge
Category of record
E02
DXA0KA
PC-EPC Sol. Disc.
PUMP
Electrical system
E02
DXA0KB
PC-EPC Sol. S/C
PUMP
Electrical system
DXE0KA
LS-EPC Sol. Disc.
PUMP
Electrical system
DXE0KB
LS-EPC Sol. S/C
PUMP
Electrical system
DXE4KA
PUMP
Electrical system
DXE4KB
PUMP
Electrical system
DY20KA
MON
Electrical system
DY20MA
MON
Electrical system
DY2CKB
Washer Drive Short
MON
Electrical system
DY2DKB
Wiper Drive (For) Short
MON
Electrical system
DY2EKB
Wiper Drive (Rev) Short
MON
Electrical system
Reference
document No.
Troubleshooting
by failure code
(Display of code),
Part 3
SEN03603-00
This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN04150-00
SEN04150-00
40 Troubleshooting
Before carrying out troubleshooting when failure code is displayed
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally.
Type of
power supply
Fusible link
Fuse No.
Fuse
capacity
10A
Pump controller
20A
Pump controller (Solenoid power supply)
Destination of power
PPC oil pressure lock solenoid valve

Switch power
supply
Switch power
supply
Switch power
supply
Constant
power supply
F04
(65A)
F04
(65A)
F04
(65A)
F05
(30A)
Switch power Starting switch

supply
ACC
20A
Machine monitor
Wiper motor
Cigarette lighter
10A
10A
Horn relay, horn
10A
Electrical intake air heater relay
10A
Rotary lamp (If equipped)
10A
Relay for lamp
10A
10
10A
11
20A
Windshield washer motor
Radio, speaker
Left-hand knob switch (pump controller input)
(Spare)
Air conditioner compressor electromagnetic clutch
12
20A
(Spare)
13
20A
Lamp, lamp relay drive
14
10A
Optional power supply (1)
15
10A
Travel alarm, 12V power supply

Radio (backup power supply)
16
10A
17
10A
18
10A
(Spare)
19
30A
Engine controller
20
5A
Engine controller (ACC signal)
Room lamp
Starting switch
Machine monitor
PC400, 450-7E0
40 Troubleshooting
SEN04150-00
Locations of fusible links and fuse No.
PC400, 450-7E0
SEN04150-00
40 Troubleshooting
Troubles that occur when controller power supply of pump controller is defective
a The controller power supply (F01-1) of the pump controller drives the controller system. Accordingly, if it
is turned off, the controller cannot control the system and the troubles shown below occur simultaneously (The following is an example of the troubles).
q
The working mode cannot be changed.
q
The auto-decelerator does not work or is not reset.
q
The travel speed does not change.
q
The power maximizing function does not work.
q
The swing holding brake cannot be reset automatically.
q
The machine deviates during travel.
Troubles that occur when solenoid power supply of pump controller is defective
a The solenoid power supply (F01-2) of the pump controller is used by the controller to drive the solenoids
and relays. Accordingly, if the solenoid power supply is turned off, when the controller outputs the power
to the solenoids or relays, the power is not supplied to any of the solenoids and relays and all or some of
the following failure codes are displayed simultaneously.
q
[DW43KA], [DW43KB]: Travel speed solenoid system
q
[DW45KA], [DW45KB]: Swing holding brake solenoid system
q
[DW4WKA], [DW4WKB]: Bucket dump prohibit solenoid system
q
[DW91KA], [DW91KB]: Travel junction solenoid system
q
[DWA2KA], [DWA2KB]: Service solenoid system
q
[DWK0KA], [DWK0KB]: 2-stage relief solenoid system
q
[DXA8KA], [DXA8KB]: PC-EPC (F) solenoid system
q
[DXA9KA], [DXA9KB]: PC-EPC (R) solenoid system
q
[DXE0KA], [DXE0KB]: LS-EPC solenoid system
q
[DXE4KA], [DXE4KB]: Service current EPC system (if attachment is installed)
q
[DXE5KA], [DXE5KB]: Merge-divider main solenoid system
q
[DXE6KA], [DXE6KB]: Merge-divider LS solenoid system
a
If the above problems occur, check the related fuse (F01-2) and inlet voltage of the pump controller.
1) Disconnect connector CP03 of the controller and connect a T-adapter to the wiring harness side.
2) Turn the starting switch ON.
3) Measure the voltage between each of pins (2), and (12) and each of pins (27), (32), and (33).
* Pins (2) and (12) are the power supply and pins (27), (32), and (33) are the chassis ground.
* If the voltage is 20 30 V, it is normal.
PC400, 450-7E0
40 Troubleshooting
a
SEN04150-00
Power supply connector (CP03) of pump controller
PC400, 450-7E0
SEN04150-00

2008 KOMATSU
All Rights Reserved
10
SEN03600-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting

Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and troubleshooting steps......................................................................................................... 5
Information in troubleshooting table................................................................................................................ 6
Connection table for connector pin numbers .................................................................................................11
T- branch box and T- branch adapter table ................................................................................................... 47
PC400, 450-7E0
SEN03600-00
40 Troubleshooting
Points to remember when troubleshooting

k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immediately
any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator. For
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior
investigation and to carry out troubleshooting
in accordance with the fixed procedure.
3.
Points to ask user or operator

1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failureWhen were these repairs carried
out?
6) Has the same kind of failure occurred
before?
5.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or
information.
6.
Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again.To prevent this, always investigate why the problem occurred. Then, remove
the root cause.
4.
Check before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measurement that may make the problem worse.
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
Sequence of events in troubleshooting
PC400, 450-7E0
SEN03600-00
40 Troubleshooting
Checks before troubleshooting

Item
Add fuel
Clean and drain
3. Check of hydraulic oil level
Add oil
Clean and drain
Add oil
Add oil
7. Check of coolant level
Add coolant
8. Check of dust indicator for clogging
Clean or replace
9. Check of hydraulic oil filter
Replace
1. Check of battery terminals and wiring for looseness and

corrosion
Retighten or replace
2. Check of alternator terminals and wiring for looseness and

corrosion
3. Check of starting motor terminals and wiring for looseness

and corrosion
Repair
Repair
Bleed air
20 30 V
Replace
2. Check of electrolyte level
Add or replace
3. Check of wires for discoloration, burn, and removal of

cover
Replace
4. Check for released wire clamp and drooping wire
Repair
5. Check of wires for wetness (Check connectors and terminals for wetness, in particular)
Disconnect the connectors and dry
6. Check of fuse for disconnection and corrosion
Replace
7. Check of alternator voltage (while engine speed is at middle or higher)
After operating for

several minutes:
27.5 29.5 V
Replace
8. Check of battery relay for operating sound (when starting

switch is turned ON or OFF)
Replace
1. Check of battery voltage (with engine stopped)
Remedy
2. Check of fuel for foreign matter
Hydraulic, 1. Check for abnormal noise and smell

Mechanical 2. Check of oil leakage
equipment 3. Bleeding air
Electric,
electrical
equipment
Criterion
1. Check of level and type of fuel
4. Check of hydraulic oil strainer

Lubricating
5. Check of swing machinery oil level
oil, Coolant
6. Check of level and type of engine oil (in oil pan)
Electrical
equipment
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
Classification and troubleshooting steps
Classification of troubleshooting
Mode
Contents
Display of code Troubleshooting by failure code

E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Troubleshooting steps
If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by
performing the following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [3] switch at panel switch section to display
failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
2.
Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality
record function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3.
Procedure for troubleshooting to be taken when action code is not displayed and no failure code
is recorded in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of Phenomena looking like troubles and troubleshooting Nos., and then carry out troubleshooting corresponding to that phenomenon in the E-mode, H-mode, or S-mode.
PC400, 450-7E0
SEN03600-00
40 Troubleshooting
Information in troubleshooting table

a
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code
Failure code
Display on
Display on machine
machine monimonitor
tor
Contents of
trouble
Trouble
Trouble name displayed in abnormality record machine monitor
Contents of trouble detected by machine monitor or controller
Action of
Action taken by machine monitor or controller to protect system or devices when engine conmachine monitroller detects trouble
tor or controller
Problem that
appears on
machine
Problem that appears on machine as result of action taken by machine monitor or controller
(shown above)
Related information
Information related to detected trouble or troubleshooting
Cause
Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
2
Possible causes
and standard
value in normal
state
<Troubles in wiring harness>

Disconnection
Connector is connected imperfectly or wiring harness is broken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each other
abnormally.
Possible causes of trouble

(Given numbers are reference numbers, which do not <Precautions for troubleshooting>
indicate priority)
(1) Method of indicating connector No. and handling of Tadapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
If connector No. has no marks of male and female,
disconnect connector and insert T-adapters in both male
side and female side.
If connector No. has marks of male and female, disconnect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise
4
specified.
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or harness entered
on rear side.
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

q
q
PC400, 450-7E0
Connector No.: Indicates (Model Number of pins) and

(Color).
Connector No. and pin No. from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
Arrow (): Roughly shows the location on the machine.
SEN03600-00
40 Troubleshooting
Possible Problems and Troubleshooting No.

Troubleshooting
No.
Phenomena looking like troubles
Display of
code
E-mode
H-mode
S-mode
Phenomena related to action code and failure code

1
An action code is displayed on machine monitor
When abnormality record is checked, failure code is displayed in electrical system abnormality record
When abnormality record is checked, failure code is displayed in mechanical system abnormality record
According to
displayed
code
Phenomena related to engine

4
5
6
7
Starting performance is poor (it always starts up slowly)
S-1
Engine does not rotate
E-1
S-2 (1)
Engine rotates, but exhaust gas does not

Engine does
come out
not start
Engine emits exhaust gas, but it does not
start
Engine does not pick up smoothly (follow-up performance

is poor)
Engine stops during operations
S-2 (2)
S-2 (3)
S-3
H-2
S-4
10 Engine rotation is unstable (it hunts)
S-5
11 Engine lacks output or power
H-1
S-6
12 Exhaust smoke is black (incomplete combustion)
S-7
13 Oil consumption is excessive or exhaust smoke is blue
S-8
14 Oil becomes contaminated quickly
S-9
15 Fuel consumption is excessive
S-10
16
Oil is in coolant, coolant spurts back or coolant level goes

down
S-11
17 Oil level rises (Entry of coolant or fuel)
S-13
18 Abnormal noise is made
S-15
19 Vibration is excessive
S-16
20 Auto-decelerator does not operate
E-2
21 Automatic warm-up system does not operate
E-3
22 Preheater does not operate
E-4
H-5
Phenomena related to work equipment, swing and travel

23
Speed or power of whole work equipment, travel, and

swing is low
24 Engine speed lowers extremely or engine stalls

25
Work equipment, swing, and travel mechanism do not

move
E-5
H-1
S-6
H-2
S-4
H-3
26 Abnormal sound comes out from around hydraulic pump
H-4
27 Fine control performance or response is low
H-6
Phenomena related to work equipment

28 Speed or power of boom is low
E-18,19
H-7
29 Speed or power of arm is low
E-20, 21
H-8
30 Speed or power of bucket is low
E-22, 23
H-9
31 Boom, arm, or bucket does not move
H-10
32 Hydraulic drift of work equipment is large
H-11
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
Troubleshooting
No.
Display of
code
E-mode
33 Time lag of work equipment is large

34
H-mode
S-mode
H-12
When part of work equipment is relieved singly, other

parts of work equipment move
35 Power maximizing function does not work
H-13
E-6, 18 23
H-14
Phenomena related to compound operation

36
In compound operation of work equipment, speed of part

loaded more is low
H-16
37
When machine swings and raises boom simultaneously,

boom rising speed is low
H-17
38
When work equipment and travels simultaneously, travel

speed lowers largely
H-18
Phenomena related to travel

39 Machine deviates during travel
H-19
40 Travel speed is low

41 Machine is not steered well or steering power is low
42 Travel speed does not change or travel speed is low or high
E-25
H-20
E-25, 26
H-21
E-25
H-22
43 Travel system does not move (only one side)
H-23
Phenomena related to swing

44 Upper structure does not swing
E-24
45 Swing acceleration or swing speed is low
H-24
H-25
Upper structure overruns remarkably when it stops swinging
H-26
47 Large shock is made when upper structure stops swinging
H-27
Large sound is made when upper structure stops swing48

ing
H-28
49 Hydraulic drift of swing
H-29
46
Phenomena related to machine monitor (Operator menu: ordinary screen)

50 Machine monitor does not display any items
E-7
51 Machine monitor does not display some items
E-8
52
Contents of display by machine monitor are different from

applicable machine
53
Radiator coolant level monitor lights up in red during

check before starting
B@BCZK
54
Engine oil level monitor lights up in red during check

before starting
B@BAZK
55
Maintenance interval monitor lights up in red during check

before starting
56
Charge level monitor lights up in red while engine is running
E-9
See the Operation and Maintenance Manual.

AB00KE
57 Fuel level monitor lights up in red while engine is running
E-10
58
Air cleaner clogging monitor lights up in red while engine

is running
AA10NX
59
Engine coolant temperature monitor lights up in red while

engine is running
B@BCNS
60
Hydraulic oil temperature monitor lights up in red while

engine is running
B@HANS
PC400, 450-7E0
SEN03600-00
40 Troubleshooting
Troubleshooting
No.
61
Engine coolant temperature gauge does not indicate normally
E-11
62
Hydraulic oil temperature gauge does not indicate normally
E-12
Display of
code
E-mode
63 Fuel level gauge does not indicate normally
E-13
64 Swing lock monitor does not indicate normally
E-14
65
Machine monitor display anything even when operated on

monitor switch section
H-mode
S-mode
E-15
66 Windshield wiper does not operate
E-16
67 Machine push-up function does not work normally
E-17
H-15
Phenomena related to machine monitor (Service menu: special functions screen)

Monitoring function does not display Boom RAISE nor68
mally
69
Monitoring function does not display Boom LOWER normally
E-18
E-19
70 Monitoring function does not display Arm IN normally
E-20
71 Monitoring function does not display Arm OUT normally
E-21
72
Monitoring function does not display Bucket CURL normally
E-22
73
Monitoring function does not display Bucket DUMP normally
E-23
74 Monitoring function does not display Swing normally
E-24
75 Monitoring function does not display Travel normally
E-25
Monitoring function does not display Travel Steering nor76

mally
E-26
77 Monitoring function does not display Service normally
E-27
Phenomena related to KOMTRAX

78 KOMTRAX system does not operate normally
E-28
Others
79 Air conditioner does not operate
E-29
80 Travel alarm does not sound or does not stop sounding
E-30
81 Horn does not sound
E-31
10
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
Connection table for connector pin numbers
(Rev. 2007.12)
The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC400, 450-7E0
11
SEN03600-00
12
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
13
SEN03600-00
14
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
15
SEN03600-00
16
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
17
SEN03600-00
18
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
19
SEN03600-00
20
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
21
SEN03600-00
22
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
23
SEN03600-00
24
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
25
SEN03600-00
26
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
27
SEN03600-00
28
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
29
SEN03600-00
30
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
31
SEN03600-00
32
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
33
SEN03600-00
34
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
35
SEN03600-00
36
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
37
SEN03600-00
38
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
39
SEN03600-00
40
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
41
SEN03600-00
42
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
43
SEN03600-00
44
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03600-00
45
SEN03600-00
46
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
SEN03600-00
T- branch box and T- branch adapter table
(Rev. 2007.12)
1
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
q q
21
MIC-21P
q q q
q q
MIC-9P
q q q
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-3470 Case
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-2850 Case
799-601-4350 T-box (for DRC 60, ECONO)
60
799-601-4360 Case
799-601-7010 Adapter for X (T-adapter)
X2P
q q q
X3P
q q q
q
q
X4P
q q q
SW6P
q q q
q q q
SW8P
12
SW12P
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
q
q
M2P
q q q
M3P
q q q
PC400, 450-7E0
47
SEN03600-00
40 Troubleshooting
q q q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
16
S16PW
12
S12PW
Out of kit
S8P
799-601-4201
799-601-4101
799-601-9300
799-601-9200
q q q
M8P
799-601-9100
M6P
799-601-9000
799-601-8000
799-601-7500
799-601-7400
q q q
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
q
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (Gray)
DT8GR
799-601-9070 Adapter for DT (Black)
DT8B
799-601-9080 Adapter for DT (Green)
DT8G
799-601-9090 Adapter for DT (Brown)
DT8BR
799-601-9110 Adapter for DT (Gray)
12
DT12GR
799-601-9120 Adapter for DT (Black)
12
DT12B
799-601-9130 Adapter for DT (Green)
12
DT12G
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
48
24
q q
q q
q q
q q
PC400, 450-7E0
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
SEN03600-00
Number of pins
40 Troubleshooting
799-601-9330 Case
799-601-9340 Case
40
DRC-40
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q
FCIG
q q
FCIB
q q
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q
Socket for engine (CRI-T3)

799-601-4190*
Commonrail pressure
1,2,3L
q q
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q

799-601-4340*
Pump actuator
2,PA
q q
1,2,3,4T
799-601-9430*
795-799-5540*
799-601-4140

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM

Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL

799-601-4160
799-601-4230*
799-601-4380*

Oil pressure switch

Air intake pressure/temperature
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
q
q q
799-601-4260 Adapter for controller (ENG)
DTP4
50
DRC50
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280 Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.

PC400, 450-7E0
49
SEN03600-00

2008 KOMATSU
All Rights Reserved
50
SEN03601-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting
Troubleshooting by failure code

(Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std ...................................................................................................... 3
Failure code [AA10NX] Aircleaner Clogging ................................................................................................... 4
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 6
Failure code [B@BAZG] Eng Oil Press. Low.................................................................................................. 8
Failure code [B@BAZK] Eng. Oil Level Low................................................................................................. 10
Failure code [B@BCNS] Eng. Water Overheat............................................................................................. 12
Failure code [B@BCZK] Eng. Water Lvl Low................................................................................................ 14
Failure code [B@HANS] Hydr. Oil Overheat................................................................................................. 16
Failure code [CA111] ECM Critical Internal Failure....................................................................................... 18
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 20
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 21
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ 23
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 24
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 26
PC400, 450-7E0
SEN03601-00
40 Troubleshooting
Failure code [CA135] Eng Oil Press Sensor High Error................................................................................ 27

Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 29
Failure code [CA144] Coolant Temp Sens High Error................................................................................... 30
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 32
Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 33
Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 35
Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 35
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 36
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 38
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 39
Failure code [CA234] Eng Overspeed .......................................................................................................... 41
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 42
Failure code [CA263] Fuel Temp Sensor High Error..................................................................................... 44
Failure code [CA265] Fuel Temp Sensor Low Error...................................................................................... 46
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 47
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 48
Failure code [CA273] PCV2 Short Error ....................................................................................................... 50
Failure code [CA274] PCV2 Open Error ....................................................................................................... 51
Failure code [CA322] Inj #1 Open/Short Error .............................................................................................. 52
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [A000N1] Eng. Hi Out of Std

Action code
Failure code
A000N1
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Eng. Hi Out of Std

(Mechanical system)
While the engine was running, engine speed exceeded 2,350 rpm for more than 10 seconds.
None in particular.
If cause of failure disappears, system resets itself.
If machine is operated as it is, engine may be damaged.
Input from the engine speed sensor (engine speed) can be checked with monitoring function.
(Code 01002: Engine speed)
Cause
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Defective engine mechanical system
Check for any internal or external factor that might cause the excessive engine high idle speed for troubleshooting of engine mechanical system.
2 Defective engine controller
Since trouble is in system, troubleshooting cannot be carried out. (If

no visible error appears on the machine, the controller can be continuously used as it is.)
SEN03601-00
40 Troubleshooting
Failure code [AA10NX] Aircleaner Clogging

Action code
Failure code
AA10NX
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Aircleaner Clogging
(Mechanical system)
While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected
with GND).
None in particular.

If an air cleaner clogging caution symbol appears on the machine monitor while the engine is running, this failure code will be recorded.
Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code 04501: Monitor Input 2)
Cause
1
Clogging of air cleaner

(when system is normal)
Check the air cleaner for clogging and then clean or

replace it if clogged.
Prepare with starting switch OFF, then start engine and

carry out troubleshooting.
Defective air cleaner clog2 ging switch (internal disconnection)
P23 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Air cleaner
Resistance
Value in normal state
Max. 1 z
Value when clogged
Min. 1 Mz

Disconnection in wiring harness

Wiring harness between P02 (female) (5)
3 (Disconnection in wiring or
P23 (female) (1)
defective contact in connector)
chassis ground
a
4 Defective machine monitor
Resistance
Max. 1 z
Resistance
Max. 1 z

P02
Air cleaner
Voltage
Between (5)
chassis ground
Max. 1 V
Value when clogged
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to air cleaner clogging switch of machine monitor
PC400, 450-7E0
SEN03601-00
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low

Action code
Failure code
AB00KE
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Charge Voltage Low

(Mechanical system)
While engine is running, power generation signal from the alternator is not input.
None in particular.
If machine is operated as it is, battery may not be charged.

If a charge level caution symbol appears on the machine monitor while the engine is running, this
failure code will be recorded.
Input from alternator (voltage) can be checked with monitoring function.
(Code 04300: Charge voltage)
Cause
a
1
Defective alternator
(Low power generation)
Alternator
Engine speed
Voltage
Medium or higher
27.5 29.5 V
Prepare with starting switch OFF, then carry out trouble-

shooting without turning starting switch ON.
Resisdefective contact in connector) Wiring harness between P02 (female) (11)
J02 Alternator R terminal
tance
a
3
Max. 1 z
Prepare with starting switch OFF, then turn starting

switch ON and carry out troubleshooting.
Ground fault in wiring harness

(Short circuit with GND circuit) Wiring harness between P02 (female) (11)
J02 Alternator R terminal, D01 (female)
(6) M17 (female) (2)

Between R terminal
chassis ground
Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz

P02
Engine speed
Voltage
Between (11)
chassis ground
Medium or higher
27.5 29.5 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to starting and charge of machine monitor
PC400, 450-7E0
SEN03601-00
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press. Low

Action code
Failure code
B@BAZG
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Eng Oil Press. Low

(Mechanical system)
While engine was running, signal circuit of engine oil pressure switch detected low engine oil pressure (sensor contact opened).
Displays engine oil pressure monitor on machine monitor.
Engine oil pressure sensor signal is input to engine controller and then transmitted to machine monitor.
Method of reproducing failure code: Start engine.
Cause
Lowering of engine oil pres1 sure
Determine the cause and check the damage to the

engine and then modify it.

Defective engine oil pressure

2 sensor
(Internal defect)
Possible causes
and standard
value in normal
state
POIL (male)
Engine
Resistance
Between (3)
chassis ground
When started
Min. 1 Mz
When stopped
Max. 1 z

Resisdefective contact in connector) Wiring harness between CE01 (female) (37)
POIL (female) (1)
tance
a
4
Max. 1 z
Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

(Short circuit with GND circuit) Wiring harness between CE01 (female) (37)
POIL (female) (1) and chassis ground (when
engine is started)
Resistance
Min. 1 Mz

CE01
Engine
Resistance
Between (37)
chassis ground
When started
Min. 1 Mz
When stopped
Max. 1 z
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to engine oil pressure
PC400, 450-7E0
SEN03601-00
40 Troubleshooting
Failure code [B@BAZK] Eng. Oil Level Low

Action code
Failure code
B@BAZK
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Eng. Oil Level Low

(Machine monitor system)
When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
detected low engine oil level (sensor contact opened).
Displays engine oil level monitor on machine monitor.
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Engine oil level switch signal can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON.
Cause
1
Lowering of engine oil level

Defective engine oil level

2 switch
(Internal disconnection)
Possible causes
and standard
value in normal
state
Check the engine oil level and add new oil.

(If this phenomenon frequently occurs, investigate the
cause.)
P44 (male)
Between (1) chassis ground
Engine oil level
Resistance
Max. 1 z
Value when coolant

level is low
Min. 1 Mz

P44 (female) (1)
tance
a
Max. 1 z

P02
Between (8)
chassis ground
Engine oil level
Voltage
Max. 1 V
Value when coolant

level is low
20 30 V
Circuit diagram related to engine oil level switch of machine monitor
10
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03601-00
11
SEN03601-00
40 Troubleshooting
Failure code [B@BCNS] Eng. Water Overheat

Action code
Failure code
B@BCNS
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Eng. Water Overheat

(Engine controller system)
While engine was running, signal circuit of engine coolant temperature sensor detected overheating
of engine coolant (above 102C).
Displays engine coolant temperature monitor with red on machine monitor.
Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Engine coolant temperature can be checked with monitoring function (Code 04107: Engine coolant
temperature)
Method of reproducing failure code: Start engine.
Cause
1
Overheating of engine
Defective engine coolant

2 temperature sensor
(Internal short circuit)
Possible causes
and standard
value in normal
state

engine and then modify it.
TWTR (male)
Between (A) (B)

Between (A)
chassis ground
Resistance
90 3.5 kz
10 100C
Min. 1 Mz
Ground fault in wiring harshooting without turning starting switch ON.

3 ness
Resis(Short circuit with GND circuit) Between wiring harness of CE01 (female)
(15) TWTR (female) (A) and chassis ground
tance
a
12
Min. 1 Mz
CE01 (female)
Engine coolant
temperature
Resistance
Between (15)
chassis ground
10 100C
90 3.5 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to engine coolant temperature sensor of machine monitor
PC400, 450-7E0
13
SEN03601-00
40 Troubleshooting
Failure code [B@BCZK] Eng. Water Lvl Low

Action code
Failure code
B@BCZK
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Eng. Water Lvl Low

(Mechanical system)
While engine was running, signal circuit of radiator coolant level switch was opened (disconnected
with GND).
None in particular.
If machine is operated as it is, engine may overheat.

If radiator coolant level caution symbol appears on the machine monitor while the engine is running,
this failure code will be recorded.
Input from the radiator coolant level switch (ON/OFF) can be checked with monitoring function.
Cause
1
Lowering of radiator coolant level a

Check the coolant level and add coolant.

(If this phenomenon frequently occurs, investigate the cause.)
Defective radiator coolant

2 level switch
(internal disconnection)
P24 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Radiator coolant level
Resistance
Max. 1 z
Value when coolant

level is low
Min. 1 Mz

defective contact in connector) P24 (female) (1)
chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

P02
Between (3)
chassis ground
14
Engine coolant
temperature
Voltage
Max. 1 V
Value when coolant

level is low
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to radiator coolant level switch of machine monitor
PC400, 450-7E0
15
SEN03601-00
40 Troubleshooting
Failure code [B@HANS] Hydr. Oil Overheat

Action code
Failure code
B@HANS
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble
Hydr. Oil Overheat

(Mechanical system)
While engine was running, signal of hydraulic oil temperature sensor is over 102C.
None in particular.
If machine is operated as it is, hydraulic components may be seized.

If hydraulic oil temperature gauge enters red range on the machine monitor while the engine is running, this failure code will be recorded.
Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
(Code 04402: Hydraulic oil temperature sensor voltage)
Cause
1
Hydr. Oil Overheat

Defective hydraulic oil tem2 perature sensor

Possible causes
and standard
value in normal
state

hydraulic components and then modify it.
P22 (male)
Between (1) (2)

Between (2)
chassis ground

3
(Short circuit with GND circuit)
Min. 1 Mz
Resistance
Min. 1 Mz
P02 (female)
Hydraulic oil
temperature
Between (12) (13)

Between (12)
chassis ground
16
Resistance
90 3.5 kz
10 100C

P22 (female) (2) and chassis ground
Hydraulic oil
temperature
Resistance
90 3.5 kz
10 100C
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to hydraulic oil temperature sensor of machine monitor
PC400, 450-7E0
17
SEN03601-00
40 Troubleshooting
Failure code [CA111] ECM Critical Internal Failure

Action code
Failure code
E10
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
ECM Critical Internal Failure

Incompatibility of data occurred in engine controller.

None in particular.
Operations are continued, but engine may stop during operations or may not start in stopped state.
Related
information
Cause
1 Defective fuse

Fuse or circuit breaker on applicable machine side may be defective. Check it directly.
(If fuse is broken or circuit breaker is shut down, circuit probably
has ground fault.)
Possible causes
and standard
value in normal
state
a
3
Max. 1 z
Max. 1 z
Ground fault in wiring harness Wiring harness between CE03 (female) (3)
(Short circuit with GND circuit) battery (+) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between CE03 (female) (1)

chassis ground
Resistance
Min. 1 Mz
a
18

Resis2
(Disconnection in wiring or
battery (+)
tance
Resischassis ground
tance

CE03
Voltage
Between (3) (1)
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to controller power supply
PC400, 450-7E0
19
SEN03601-00
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action code
Failure code
E10
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor.
None in particular.
Engine cannot be started. (Engine is stopped.)
Engine stops (during operations).
Related
information
Cause
Defective Ne speed sensor
1
system
Possible causes
and standard
value in normal
state
Carry out troubleshooting for failure code [CA689].
Defective Bkup speed sensor

system
Defective installation of Ne
speed sensor
Ne speed sensor may be installed defectively. Check it directly.

(Defective installation of sensor itself, internal defect of flywheel, etc.)
Defective installation of Bkup

speed sensor
Bkup speed sensor may be installed defectively. Check it directly.

(Defective installation of sensor itself, internal defect of supply
pump, etc.)
Defective connection of sensor Ne speed sensor and Bkup speed sensor may be connected
connector (Wrong connection) defectively (or connected to wrong parts). Check them directly.
20
If causes 1 5 are not detected, engine controller may be defective.

(Since trouble is in system, troubleshooting cannot be carried out.)
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA122] Chg Air Press Sensor High Error

Action code
Failure code
E11
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High pressure error occurred in charge air pressure sensor circuit.

Fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
Engine does not accelerate easily.
Related
information
Cause
Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble1
ply system
shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
Defective charge air pressure
2 sensor
(Internal defect)
PIM
Between (1) (3)

PIM (female) (1)
defective contact in connector) Wiring harness between CE01 (female) (44)
PIM (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

PIM (female) (3)
Resistance
Max. 1 z
Between wiring harness of CE01 (female)

Ground fault in wiring harness (37) PIM (female) (1) and chassis ground
4
(Short circuit with GND circuit) Between wiring harness of CE01 (female)
(44) PIM (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(47) PIM (female) (3) and chassis ground
Resistance
Min. 1 Mz

PIM (female) (1) and between CE01
(female) (44) PIM (female) (2)
Resistance
Min. 1 Mz
Short circuit in wiring harness

(with another wiring harness) Wiring harness between CE01 (female) (37)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a

switch ON or start engine and carry out troubleshooting.
CE01
Between (37) (47)
PC400, 450-7E0
4.75 5.25 V
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes
and standard
value in normal
state
Voltage
Power supply
Voltage
Power supply
4.75 5.25 V
21
SEN03601-00
40 Troubleshooting
Circuit diagram related to charge pressure sensor
22
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA123] Chg Air Press Sensor Low Error

Action code
Failure code
E11
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low pressure error occurred in charge air pressure sensor circuit.

Fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
Engine does not accelerate easily.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

23
SEN03601-00
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action code
Failure code
E14
CA131
Contents of
trouble
Action of
controller
Trouble

High error occurred in throttle sensor circuit.

Use a signal other than throttle sensor to set the throttle position and continues operation.
Problem that
appears on
machine
Related
information
Cause
ply system
Defective fuel control dial

(Internal defect)
P20 (male)
Possible causes
and standard
value in normal
state
Resistance
Between (1) (3)
4.0 6.0 kz
Between (2) (1)
0.25 5.0 kz
Between (2) (3)
0.25 5.0 kz

Disconnection in wiring harness P20 (female) (1)
P20 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

P20 (female) (3)
Resistance
Max. 1 z

Ground fault in wiring harness P20 (female) (1) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a
24

CE02
Voltage
Between (22) (23)
Voltage
4.75 5.25 V
Between (9) (23)
Signal
0.5 4.5 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to fuel control dial throttle sensor
PC400, 450-7E0
25
SEN03601-00
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action code
Failure code
E14
CA132
Contents of
trouble
Action of
controller
Trouble

Low error occurred in throttle sensor circuit.

Use a signal other than throttle sensor to set the throttle position for control.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
26
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA135] Eng Oil Press Sensor High Error

Action code
Failure code
E15
CA135
Contents of
trouble
Action of
controller
Trouble
Eng Oil Press Sensor High Error

High pressure error occurred in engine oil pressure sensor circuit.

Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Cause
ply system
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
2
Defective oil pressure sensor

(Internal defect)
POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Possible causes
and standard
value in normal
state

POIL (female) (1)
POIL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

POIL (female) (3)
Resistance
Max. 1 z

Ground fault in wiring harness (37) POIL (female) (1) and chassis ground
4
(47) POIL (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(13) POIL (female) (3) and chassis ground
Resistance
Min. 1 Mz

POIL (female) (1) and between CE01
(female) (47) POIL (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a

CE01
Between (37) (47)
PC400, 450-7E0
Voltage
Power supply
4.75 5.25 V
27
SEN03601-00
40 Troubleshooting
Circuit diagram related to oil pressure sensor
28
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA141] Eng Oil Press Sensor Low Error

Action code
Failure code
E15
CA141
Contents of
trouble
Action of
controller
Trouble
Eng Oil Press Sensor Low Error

Low pressure error occurred in engine oil pressure sensor circuit.

Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

29
SEN03601-00
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action code
Failure code
E15
CA144
Contents of
trouble
Action of
controller
Trouble

High temperature error occurred in coolant temperature sensor circuit.

Fixes coolant temperature value (90C) and continues operation.
Problem that
appears on
machine
Related
information
Cause
TWTR (male)
Defective coolant tempera1 ture sensor

(Internal defect)
Between (A) (B)
a
Possible causes
and standard
value in normal
state
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z

TWTR (female) (A)
TWTR (female) (B)
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z

(Short circuit with GND circuit) Between wiring harness of CE01 (female) (15)
TWTR (female) (A) and chassis ground
Resistance
Min. 1 Mz
CE01 (female)

Between (15) (38)
30
Coolant temperature
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to coolant temperature sensor
PC400, 450-7E0
31
SEN03601-00
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action code
Failure code
E15
CA145
Contents of
trouble
Action of
controller
Trouble

Low temperature error occurred in coolant temperature sensor circuit.

Fixes coolant temperature value (90C) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
32
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA153] Chg Air Temp Sensor High Error

Action code
Failure code
E15
CA153
Contents of
trouble
Action of
controller
Trouble

High temperature error occurred in charge air temperature sensor circuit.

Fixes charge air temperature (air intake temperature) at 70C and continues operation.
Problem that
appears on
machine
Related
information
Cause
TIM (male)
Defective charge air temper1 ature sensor

(Internal defect)
Between (A) (B)
Between (A)
chassis ground
a
Possible causes
and standard
value in normal
state
Air intake temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
Whole area
Min. 1 Mz

TIM (female) (A)
TIM (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Resis(23) TIM (female) (A) and chassis ground
tance
a
CE01 (female)

Between (23) (47)
PC400, 450-7E0
Min. 1 Mz
Air intake temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
33
SEN03601-00
40 Troubleshooting
Circuit diagram related to charge temperature sensor
34
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA154] Chg Air Temp Sensor Low Error

Action code
Failure code
E15
CA154
Contents of
trouble
Action of
controller
Trouble

Low temperature error occurred in charge air temperature sensor circuit.

Fixes charge air temperature (air intake temperature) at 70C and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause

Failure code [CA187] Sens Supply 2 Volt Low Error

Action code
Failure code
E15
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low voltage error occurred in sensor power supply 2 (5V) circuit.

Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
Oil pressure sensor sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Ambient pressure sensor sets ambient pressure to default (52.44 kPa {0.5 kg/cm2}) and continues
operation.
Charge air pressure sensor fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.0 kg/cm2}) and continues
operation.
EGR valve lift sensor limits output, and closes EGR and bypass valves.
Bypass valve lift sensor limits output.
Engine output lowers.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

35
SEN03601-00
40 Troubleshooting
Failure code [CA221] Ambient Press Sens High Error

Action code
E11
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Failure code
CA221
Trouble

High pressure error occurred in ambient pressure sensor circuit.

Sets ambient pressure to default (52.44 kPa {0.52 kg/cm2}) and continues operation.
Cause
ply system
a
Defective ambient pressure
2 sensor
(Internal defect)

PAMB
Voltage
Between (1) (3)
Voltage
4.75 5.25 V
Between (2) (3)
Signal

PAMB (female) (1)
PAMB (female) (2)
PAMB (female) (3)
Possible causes
and standard
value in normal
state
Resistance
Resistance
Resistance
36
Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz

PAMB (female) (1) and between CE01
(female) (3) PAMB (female) (2)
5
Max. 1 z
Between wiring harness of CE01 (female) (37)

Ground fault in wiring harness PAMB (female) (1) and chassis ground
4
(Short circuit with GND circuit) Between wiring harness of CE01 (female) (3)
PAMB (female) (2) and chassis ground
PAMB (female) (3) and chassis ground
Resistance
Resistance
Resistance
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

CE01
Between (37) (38)
Between (3) (38)
Voltage
4.75 5.25 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to atmospheric pressure sensor
PC400, 450-7E0
37
SEN03601-00
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error

Action code
Failure code
E11
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low pressure error occurred in engine ambient pressure sensor circuit.

Sets ambient pressure to default (52.44 kPa {0.51 kg/cm2}) and continues operation.
Related
information
Possible causes
and standard
value in normal
state
38
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA227] Sens Supply 2 Volt High Error

Action code
Failure code
E15
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High voltage error occurred in sensor power supply 2 (5V) circuit.

Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
Oil pressure sensor sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Ambient pressure sensor sets ambient pressure to default (52.44 kPa {0.51 kg/cm2}) and continues
operation.
Charge air pressure sensor fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.0 kg/cm2}) and continues
operation.
EGR valve lift sensor limits output, and closes EGR and bypass valves.
Bypass valve lift sensor limits output, and closes EGR and bypass valves.
Related
information
Cause
1 Defect in related system

If another failure code is displayed, carry out troubleshooting for it.
Defective sensor
2
(Internal defect)

Disconnect sensors
at right in order. If no
error code is displayed, that sensor is
defective.
Possible causes
and standard
value in normal
state
Bkup Speed Sensor
G connector
Oil pressure sensor
POIL connector
Ambient pressure
sensor
PAMB connector
Charge air pressure

sensor
PIM connector
EGR inlet pressure

sensor
PEVA connector
EGR valve lift sensor
SEGR connector
Bypass valve lift sensor
SBP connector

each sensor (female)
each sensor (female)
a
4
PC400, 450-7E0
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) each sensor (female) and chassis ground
Resistance
Min. 1 Mz

each sensor (female) and chassis ground
Resistance
Min. 1 Mz
39
SEN03601-00
40 Troubleshooting
Cause
a
Possible causes
and standard
value in normal
state

each sensor (female) and between CE01
(female) (47) each sensor (female)
a
Resistance
Min. 1 Mz

CE01
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to sensor power supply 2 (5 V)
40
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA234] Eng Overspeed

Action code
Failure code
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Overspeed
Engine speed exceeded operating range.

Limits fuel injection rate until it lowers in operating range.
Engine speed fluctuates.
Related
information
Cause
Possible causes
and standard
value in normal
state
PC400, 450-7E0
2 Improper use
Machine may be used improperly. Teach operator proper using

method.
If causes 1 and 2 are not detected, engine controller may be defective.

41
SEN03601-00
40 Troubleshooting
Failure code [CA238] Ne Speed Sens Supply Volt Error

Action code
Failure code
E15
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High voltage error in engine Ne speed sensor power supply (5V) circuit.
Controls the engine with signal from engine Bkup speed sensor.
Engine stops during operations. (when engine Bkup speed sensor is also defective)
Engine cannot be started during operations. (when engine Bkup speed sensor is also defective)
Related
information
Cause
a
1
Defective Ne speed sensor

(Internal defect)
Disconnect sensors
defective.
a
2
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

NE (female) (2) and chassis ground
Resistance
Min. 1 Mz

NE (female) (1) and between CE01
(female) (48) NE (female) (2)
a
42
NE connector
(Short circuit with GND circuit) NE (female) (1) and chassis ground
a
4
Ne speed sensor

NE (female) (1)
NE (female) (2)
a
3
Resistance
Min. 1 Mz

CE01
Voltage
Between (16) (48)
4.75 5.25 V
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to Ne speed sensor power supply
PC400, 450-7E0
43
SEN03601-00
40 Troubleshooting
Failure code [CA263] Fuel Temp Sensor High Error

Action code
Failure code
E15
CA263
Contents of
trouble
Action of
controller
Trouble
Fuel Temp Sensor High Error

High temperature error occurred in fuel temperature sensor circuit.

Fixes fuel temperature value at 90C and continues operation.
Problem that
appears on
machine
Related
information
Cause
Defective fuel temperature
1 sensor
(Internal defect)
TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
a
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) TFUEL (female) (A) and chassis ground
44

defective contact in connector) TFUEL (female) (A)
TFUEL (female) (B)
a
3
Resistance
Min. 1 Mz
CE01 (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to fuel temperature sensor
PC400, 450-7E0
45
SEN03601-00
40 Troubleshooting
Failure code [CA265] Fuel Temp Sensor Low Error

Action code
Failure code
E15
CA265
Contents of
trouble
Action of
controller
Trouble

Low temperature error occurred in fuel temperature sensor circuit.

Fixes fuel temperature value at 90C and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
46
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA271] IMV/PCV1 Short Error

Action code
Failure code
E10
CA271
Contents of
trouble
Action of
controller
Trouble

Short circuit was detected in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause
a
Defective supply pump
1 PCV1
a
2
Possible causes
and standard
value in normal
state
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
(Short circuit with GND circuit) PCV1 (female) (1) and chassis ground
Resistance
Min. 1 Mz

PCV1 (female) (2) and chassis ground
Resistance
Min. 1 Mz
a
3

Hot short in wiring harness

(Short circuit with 24V circuit) PCV1 (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
a
CE01 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
Circuit diagram related to supply pump PCV1
PC400, 450-7E0
47
SEN03601-00
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error

Action code
Failure code
E10
CA272
Contents of
trouble
Action of
controller
Trouble
IMV/PCV1 Open Error

Open error was detected in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause
a
1
Defective supply pump PCV1

Possible causes
and standard
value in normal
state
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz

PCV1
(female) (1)
PCV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring harness PCV1 (female) (1) and chassis ground and
3
(Short circuit with GND circuit) chassis ground
Resistance
Max. 1
Mz

PCV1 (female) (2) and chassis ground and
chassis ground
Resistance
Max. 1
Mz
a
48
CE01 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4), (5)

chassis ground
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
49
SEN03601-00
40 Troubleshooting
Failure code [CA273] PCV2 Short Error

Action code
Failure code
E10
CA273
Contents of
trouble
Action of
controller
Trouble
PCV2 Short Error

Short circuit was detected in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause
a
1 PCV2
a
2
Possible causes
and standard
value in normal
state
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2)

chassis ground
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a
3


(Short circuit with 24V circuit) PCV2 (female) (1) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
a
CE01 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
50
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Failure code [CA274] PCV2 Open Error

Action code
Failure code
E10
CA274
Contents of
trouble
Action of
controller
Trouble
PCV2 Open Error

Open error was detected in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Cause
1 PCV2
Possible causes
and standard
value in normal
state
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z

PCV2
(female) (1)
PCV2 (female) (2)
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a
CE01 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Between (9), (10)

chassis ground
Min. 1 Mz
PC400, 450-7E0
51
SEN03601-00
40 Troubleshooting
Failure code [CA322] Inj #1 Open/Short Error

Action code
Failure code
E11
CA322
Contents of
trouble
Action of
controller
Trouble
Injector #1 open/short circuit error

Opening or short circuit was detected in drive circuit of No. 1 injector.

None in particular.
Problem that
appears on
machine
Combustion becomes irregular or engine hunts.

Related
information
Method of reproducing failure code: Start engine
Cause
If following failure codes are also displayed, trouble is in engine controller: [CA322], [CA324], [CA331]
a
CN1 (male)
2 Defective No. 1 injector
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
a Prepare with starting switch OFF, then carry out troubleshootDisconnection in wiring haring without turning starting switch ON.
ness
Resis3 (Disconnection in wiring or
Max. 2 z
CN1 (female) (1)
tance
defective contact in connecWiring harness between CE01 (female) (53)
Resistor)
Max. 2 z
CN1 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

CN1 (female) (1) and chassis ground
a
Defective wiring harness

connector
52
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Connecting parts between No. 1 injector engine wiring harness

engine controller may be defective. Check them directly.
Looseness of connector, breakage of lock, or breakage of seal
Corrosion, bend, breakage, push-in, or expansion of pin
Moisture or dirt in connector or defective insulation
a
Max. 2 z
Between CE01 (female) (45) each of CE01

Short circuit in wiring har(female) pins (With all wiring harness con5 ness
nectors disconnected)
(with another wiring harness)
(female) pins (With all wiring harness connectors disconnected)
Resistance
CE01 (female)
Resistance
Between (45) (53)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
Circuit diagram related to injector No. 1
PC400, 450-7E0
53
SEN03601-00
40 Troubleshooting

Action code
Failure code
E11
CA323
Contents of
trouble
Action of
controller
Trouble


None in particular.
Problem that
appears on
machine

Related
information
Cause
a
CN5 (male)
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
ness
Max. 2 z
CN5 (female) (1)
tance
Resistor)
Max. 2 z
CN5 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

a

connector
54
Resistance
Min.
100 kz
Resistance
Min.
100 kz

a
Max. 2 z

Resistance
CE01 (female)
Resistance
Between (46) (60)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
55
SEN03601-00
40 Troubleshooting

Action code
Failure code
E11
CA324
Contents of
trouble
Action of
controller
Trouble


None in particular.
Problem that
appears on
machine

Related
information
Cause
a
CN3 (male)
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
ness
Max. 2 z
CN3 (female) (1)
tance
Resistor)
Max. 2 z
CN3 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

a

connector
56
Resistance
Min.
100 kz
Resistance
Min.
100 kz

a
Max. 2 z

Resistance
CE01 (female)
Resistance
Between (55) (52)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
57
SEN03601-00
40 Troubleshooting

Action code
Failure code
E11
CA325
Contents of
trouble
Action of
controller
Trouble


None in particular.
Problem that
appears on
machine
Related
information
Cause
a
CN6 (male)
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
ness
Max. 2 z
CN6 (female) (1)
tance
Resistor)
Max. 2 z
CN6 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

a

connector
58
Resistance
Min.
100 kz
Resistance
Min.
100 kz

a
Max. 2 z

Resistance
CE01 (female)
Resistance
Between (57) (59)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
59
SEN03601-00
40 Troubleshooting

Action code
Failure code
E11
CA331
Contents of
trouble
Action of
controller
Trouble


None in particular.
Problem that
appears on
machine

Related
information
Cause

If following failure codes are also displayed, trouble is in engine
controller: [CA322], [CA324], [CA331]
a
CN2 (male)
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
ness
Max. 2 z
CN2 (female) (1)
tance
Resistor)
Max. 2 z
CN2 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

a

connector
60
Resistance
Min.
100 kz
Resistance
Min.
100 kz

a
Max. 2 z

Resistance
CE01 (female)
Resistance
Between (54) (51)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
61
SEN03601-00
40 Troubleshooting

Action code
Failure code
E11
CA332
Contents of
trouble
Action of
controller
Trouble


None in particular.
Problem that
appears on
machine

Related
information
Cause
a
CN4 (male)
Resistance
Between (1) (2)
Max. 2 z
Min. 100 kz
ness
Max. 2 z
CN4 (female) (1)
tance
Resistor)
Max. 2 z
CN4 (female) (2)
tance
Possible causes
and standard
value in normal
state

4

a

connector
62
Resistance
Min.
100 kz
Resistance
Min.
100 kz

a
Max. 2 z

Resistance
CE01 (female)
Resistance
Between (56) (58)
Max. 2 z
Min. 100 kz
PC400, 450-7E0
40 Troubleshooting
SEN03601-00
PC400, 450-7E0
63
SEN03601-00

2008 KOMATSU
All Rights Reserved
64
SEN03602-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting

Failure code [CA342] Calibration Code Incompatibility................................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 8
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 10
Failure code [CA442] Battery Voltage High Error ......................................................................................... 10
Failure code [CA449] Rail Press Very High Error ..........................................................................................11
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 12
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 14
Failure code [CA553] Rail Press High Error ................................................................................................. 14
Failure code [CA554] Rail Press Sensor In Range Error.............................................................................. 15
Failure code [CA559] Rail Press Low Error .................................................................................................. 16
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 20
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 22
PC400, 450-7E0
SEN03602-00
40 Troubleshooting
Failure code [CA757] All Persistent Data Lost Error ..................................................................................... 23

Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 24
Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................................... 26
Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................................... 27
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 28
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 30
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 32
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 33
Failure code [CA2271] EGR Valve Lift Sens High Error................................................................................ 34
Failure code [CA2272] EGR Valve Lift Sens Low Error ................................................................................ 36
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................................... 38
Failure code [CA2352] EGR Valve Sol Current Low Error ............................................................................ 40
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 41
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 42
Failure code [D110KB] Battery Relay Drive S/C ........................................................................................... 44
Failure code [D196KA] Service Return Relay Disc. ...................................................................................... 46
Failure code [D196KB] Service Return Relay S/C ........................................................................................ 48
Failure code [DA25KP] Press. Sensor Power Abnormality........................................................................... 50
Failure code [DA80MA] Auto. Lub. Abnormal. .............................................................................................. 52
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA342] Calibration Code Incompatibility

Action code
Failure code
E10
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Incompatibility of data occurred in engine controller.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

SEN03602-00
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action code
Failure code
E10
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is error in injector drive circuit.

Limits output and continues operation (limits common rail pressure).
Related
information
Cause
Check the code (injector system error code) that is displayed simultaneously. If another code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19
Fuse may be defective. Check it directly.

(If fuse is broken or circuit breaker is shut down, circuit probably has
ground fault.)
Possible causes
and standard
value in normal
state

battery (+)
chassis ground
a
4
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) battery (+) and chassis ground
Resistance
Min. 1 Mz

chassis ground
Resistance
Min. 1 Mz
a

CE03
Voltage
Between (3) (1)
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to controller power supply
PC400, 450-7E0
SEN03602-00
40 Troubleshooting
Failure code [CA352] Sens Supply 1 Volt Low Error

Action code
Failure code
E15
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low voltage error occurred in sensor power supply 1 (5V) circuit.

Common rail pressure sensor limits output and continues operation (limits common rail pressure).
Related
information
Possible causes
and standard
value in normal
state
Cause

PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03602-00
SEN03602-00
40 Troubleshooting
Failure code [CA386] Sens Supply 1 Volt High Error

Action code
Failure code
E15
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High voltage error occurred in sensor power supply 1 (5V) circuit.

Common rail pressure sensor limits output and continues operation (limits common rail pressure).
Related
information
Cause

a
2
Defective sensor
(Internal defect)
Disconnect sensors
defective.
Possible causes
and standard
value in normal
state
PFUEL connector

PFUEL (female) (1)
PFUEL (female) (3)
a
4
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) PFUEL (female) (1) and chassis ground
Resistance
Min. 1 Mz

PFUEL (female) (3) and chassis ground
Resistance
Min. 1 Mz

PFUEL (female) (1) and between CE01
(female) (47) PFUEL (female) (3)
a

Resistance
Min. 1 Mz

CE01
Voltage
Between (33) (47)
4.75 5.25 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to sensor power supply 1 (5 V)
PC400, 450-7E0
SEN03602-00
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action code
Failure code
E10
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low voltage error occurred in power supply circuit.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
Cause

Failure code [CA442] Battery Voltage High Error

Action code
Failure code
E10
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High voltage error occurred in power supply circuit.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
10
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA449] Rail Press Very High Error

Action code
Failure code
E11
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is high pressure error (level 2) in common rail pressure sensor circuit.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

11
SEN03602-00
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action code
Failure code
E11
CA451
Trouble

Contents of
trouble
High pressure error occurred in common rail pressure sensor circuit.
Action of
controller
Problem that
appears on
machine
Related
information
Cause
ply system
Defective common rail pres2 sure sensor

(Internal defect)

PFUEL
Voltage
Between (1) (3)
Power supply
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.

PFUEL (female) (1)
PFUEL (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

PFUEL (female) (3)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring harness PFUEL (female) (1) and chassis ground
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

12
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Cause
Possible causes
and standard
value in normal
state

CE01
Voltage
Between (33) (47)
4.75 5.25 V
Between (25) (47)
0.25 4.6 V
Circuit diagram related to common rail pressure sensor
PC400, 450-7E0
13
SEN03602-00
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action code
Failure code
E11
CA452
Trouble

Contents of
trouble
Low pressure error occurred in common rail pressure sensor circuit.
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause

Failure code [CA553] Rail Press High Error

Action code
Failure code
E15
CA553
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is high pressure error (level 1) in common rail pressure sensor circuit.
None in particular.
Related
information
Cause
Possible causes
and standard
value in normal
state
14
2 Use of improper fuel
Fuel used may be improper. Check it directly.

(Viscosity is high)
Defective electrical system of Electrical system of common rail pressure sensor may be defective.
common rail pressure sensor Carry out troubleshooting for failure code [CA451].
Defective mechanical system Mechanical system of common rail pressure sensor may be defecof common rail pressure sensor tive. Check it directly.
5 Defective overflow valve
Spring damage, seat wear, or ball fixing of overflow valve is suspected. Check it directly.
6 Clogged overflow piping
Overflow piping may be clogged. Check it directly.
7 Defective pressure limiter
Pressure limiter may be damaged mechanically. Check it directly.
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA554] Rail Press Sensor In Range Error

Action code
Failure code
E11
CA554
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

In range error occurred in common rail pressure sensor circuit.

Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

15
SEN03602-00
40 Troubleshooting
Failure code [CA559] Rail Press Low Error

Action code
Failure code
E15
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is rail press very low error (level 1).

Limits common rail pressure.
Related
information
Cause
2 Use of improper fuel
Fuel used may be improper. Check it directly.
a
3
Defect in low pressure circuit parts
4 Clogged fuel filter, strainer
Possible causes
and standard
value in normal
state
For more information on troubleshooting, see Note 1 on

the next page. For check of pressure in fuel low pressure
circuit, see Testing and adjusting, Checking fuel pressure.
Pressure in fuel low-pressure

circuit
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
For more information on troubleshooting, see Note 2 on

the next page.
Defective electrical system of Electrical system of supply pump PCV may be defective. Carry out troubleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
supply pump PCV
Defective common rail pres- Mechanical system of common rail pressure sensor may be defecsure sensor
tive. Check whether wiring harness is damaged.
a
7 Defective pressure limiter
For check of leakage through pressure limiter, see Testing and adjusting, Checking fuel return rate and leakage.
Leakage through pressure limiter
8 Defective injector
9 Defective supply pump
Max. 10 cc/min (at 1,600 rpm)
For check of limit return rate (spill) from injector, see Testing and adjusting, Checking fuel return rate and leakage.
Speed in rated operation
Limited return (spill) rate from

injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.
16
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Follow the procedure below to check, clean, and replace filter and strainer.
1) Gauze filter: Disassemble this filter for checking. If clogged, clean it
2) Gauze filter upstream strainer: Clean upstream strainer if gauze filter is clogged
3) Fuel filter: If failure is not remedied after steps 1) and 2) above were executed, replace fuel filter
PC400, 450-7E0
17
SEN03602-00
40 Troubleshooting
Check sheet for no-pressure feed

Machine model
Model serial No.
Engine
Engine serial No.
Working No.
Checked on
Service meter
Worker name
#
#
/
h
A. Visual check
1 Fuel leakage to outside
2 Clogged fuel tank breather
Good
Bad
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation)
3 Checking failure code
/
/
/
/
Checking monitoring information
Standard value
Measured
Code
Display item
Check conditions
Unit
(Reference value)
value
Low idle
rpm
1,930 50
*1
Engine Speed
High idle
rpm
1,000 25
Rating or equivalent
rpm
1,850
Low idle
%
0
*2
Throttle speed
High idle
%
100
*3
Injection rate command Rating or equivalent
mm3
Common
rail
pressure
4
*4
MPa
command
Common rail fuel pres*5
MPa
sure
Low idle
CA
Injection timing com*6

High idle
CA
mand
CA
*7
Boost Pressure
kPa
Engine coolant temperaLow idle

C
*8
ture
*9
Fuel temperature
Low idle
C
Checking cylinder cut-out operation (Engine speed)

FuncMeasured
Standard value
Cut-out cylinder
Check conditions
Unit
(Reference value)
tion
value
Cylinder 1
Low idle
rpm
Cylinder 2
Low idle
rpm
5
Cylinder 3
Low idle
rpm
*10
Cylinder 4
Low idle
rpm
Cylinder 5
Low idle
rpm
Cylinder 6
Low idle
rpm
Good
Bad
Good
Bad
Good
Bad
Good
Bad
Good
Bad
Good
Bad
C. Checking fuel circuit pressure

6
Pressure in fuel low-pressure

circuit
Check conditions
High idle
Standard value
(Reference value)
MPa
Min. 0.15
{Min. 1.5}
{kg/cm2}
Unit
Measured
value
D. Checking strainer and filter

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Checking leakage and fuel return
rate
11 Leakage through pressure limiter
12 Return rate from injector
18
Check conditions
No-load, 1600 rpm
1,600 rpm
1,700 rpm
1,800 rpm
1,900 rpm
2,000 rpm
Unit
cc/min
cc/min
cc/min
cc/min
cc/min
cc/min
Measured
Standard value
(Reference value)
value
Max. 10
960
Speed:
1,020
Return rate:
1,080
1,140
1,200
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
*1 to *10:
When using the monitoring function for checking, see Monitoring Code List.
Rating or equivalent:
Relieve in 1) engine full, 2) P-mode, and 3) boom RAISE.
PC400, 450-7E0
19
SEN03602-00
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action code
Failure code
E15
CA689
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Ne Speed Sensor Error

There is error in engine Ne speed sensor circuit.

Operates the engine with signal from engine Bkup speed sensor.
Engine stops during operations. (When engine Bkup speed sensor is also defective)
Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
Related
information
Cause
Defective sensor power sup- If failure code [CA238] is displayed, carry out troubleshooting for it
1
ply system
first.

NE (female) (1)
Wiring
harness between CE01 (female) (48)
NE (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

NE (female) (3)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring harness NE (female) (1) and chassis ground
3
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Defective sensor installation Ne speed sensor may be installed defectively (improper clearance),
5 or defective rotation sensor or rotation sensor parts (flywheel) may be defective. Check them
parts
directly.
6
Defective engine Ne speed

sensor
20
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to engine Ne speed sensor
PC400, 450-7E0
21
SEN03602-00
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action code
Failure code
E15
CA731
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng Bkup Speed Sens Phase Error

There is phase error in engine Bkup speed sensor circuit.

Controls the engine with signal from engine Ne speed sensor.
Engine stops during operations. (When engine Ne speed sensor is also defective)
Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
Related
information
Possible causes
and standard
value in normal
state
22
Cause
Defective engine Ne speed

1
sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for failure code [CA689].
Defective engine Bkup

speed sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for failure code [CA778].
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA757] All Persistent Data Lost Error

Action code
Failure code
E10
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

All data in engine controller are lost.

None in particular.
Related information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

23
SEN03602-00
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error

Action code
Failure code
E15
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Engine Bkup speed sensor error

There is error in engine Bkup speed sensor circuit.

Operates the engine with signal from engine Ne speed sensor.
Engine stops during operations. (When engine Ne speed sensor is also defective)
Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
Related
information
Cause
ply system

G (female) (1)
G (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

G (female) (3)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring harness G (female) (1) and chassis ground
3
G (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

G (female) (3) and chassis ground
Resistance
Min. 1 Mz

G (female) (1) and between CE01 (female)
(47) G (female) (2)
Resistance
Min. 1 Mz

(26) G (female) (3)
Resistance
Min. 1 Mz

(26) G (female) (3)
Resistance
Min. 1 Mz
Defective sensor installation Bkup speed sensor may be installed defectively (improper clear5 or defective rotation sensor ance), or rotation sensor parts (in supply pump) may be defective.
parts
Check them directly.
Defective engine Bkup
speed sensor
If causes 1 5 are not detected, engine Bkup speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)

24
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to engine Bkup speed sensor
PC400, 450-7E0
25
SEN03602-00
40 Troubleshooting
Failure code [CA1228] EGR Valve Servo Error 1

Action code
Failure code
E15
CA1228
Contents of
trouble
Trouble

There is EGR valve servo error (level 1).
Action of
controller
Performs open control.
Problem that
appears on
machine
Related
information
Cause

Defective engine oil pressure

2
system (main circuit)
Possible causes
and standard
value in normal
state
26
For check of engine oil pressure, see Testing and adjusting, Measuring engine oil pressure.
Engine
Engine oil pressure
Low idle
0.08MPa {0.8kg/cm2}
High idle
0.21MPa {2.1kg/cm2}
If engine oil pressure is not normal, carry out troubleshooting for

mechanical system. (S-12 Oil pressure lowers.)
3 Defective EGR valve oil pump
Oil pump or relief valve for EGR valve circuit may be defective.
Check it directly.
Defective EGR valve oil

pressure supply piping
Oil pressure supply piping for EGR valve circuit may be defective.
Check it directly.
Defective EGR valve oil

pressure return piping
Oil pressure return piping for EGR valve circuit may be defective.
Check it directly.
6 Defective EGR valve
EGR valve may be damaged mechanically. Check it directly.

PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA1625] EGR Valve Servo Error 2

Action code
Failure code
E11
CA1625
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is EGR valve servo error (level 2).

Limits output and continues operation.
Close EGR and bypass valves.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

27
SEN03602-00
40 Troubleshooting
Failure code [CA1633] KOMNET Datalink Timeout Error

Action code
Failure code
E0E
CA1633
Contents of
trouble
Action of
controller
Trouble

There is error in KOMNET communication circuit with machine monitor.

Operates in default mode or holds the state set when error occurred.
Problem that
appears on
machine
Related
information
Cause

CE02 (female) (47), CP02 (female) (22)
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring harness CE02 (female) (47), CP02 (female) (22),
2
(Short circuit with GND circuit) other related circuit and chassis ground
Resistance
Min. 1 Mz

CE02 (female) (46), CP02 (female) (32),
other related circuit and chassis ground
Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state
Hot short (Short circuit with

3
24V circuit) in wiring harness
Defective machine monitor,

5 engine controller, or pump
controller


Voltage
Max. 1 V

Voltage
Max. 1 V
a
Defective CAN terminal
4
resistance
28
Resistance
K02(male), K31(male)
Resistance
Between (A) (B)
108 132 z
If causes 1 4 are not detected, machine monitor, engine controller,

or pump controller may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to CAN communication of pump controller
PC400, 450-7E0
29
SEN03602-00
40 Troubleshooting
Failure code [CA2185] Throt Sens Sup Volt High Error

Action code
Failure code
E14
CA2185
Contents of
trouble
Action of
controller
Trouble

High voltage error occurred in throttle sensor power supply (5V) circuit.
Use a signal other than throttle sensor to set the throttle position for operations.
Problem that
appears on
machine
Related
information
Cause
a
1
Defective fuel control dial

(Internal defect)
Disconnect sensors
defective.
Possible causes
and standard
value in normal
state
Fuel control dial
P20 connector

P20 (female) (1)
P20 (female) (3)
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) P20 (female) (1) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

P20 (female) (1) and between CE02
(female) (23) P20 (female) (3)
a
30

Resistance
Min. 1 Mz

CE02
Voltage
Between (22) (23)
4.75 5.25 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to fuel control dial throttle sensor
PC400, 450-7E0
31
SEN03602-00
40 Troubleshooting
Failure code [CA2186] Throt Sens Sup Volt Low Error

Action code
Failure code
E14
CA2186
Contents of
trouble
Action of
controller
Trouble

Low voltage error occurred in throttle sensor power supply (5V) circuit.
Use a signal other than throttle sensor to set the throttle position for operations.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
32
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA2249] Rail Press Very Low Error

Action code
Failure code
E11
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

There is rail press very low error (level 2).

Limits common rail pressure.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

33
SEN03602-00
40 Troubleshooting
Failure code [CA2271] EGR Valve Lift Sens High Error

Action code
Failure code
E11
CA2271
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Lift Sens High Error

High error occurred in EGR valve lift sensor circuit.

Related
information
Cause
ply system
Defective EGR valve lift sensor

(Internal defect)

SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25 V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and controller, too, for another cause of trouble, and then judge.

SEGR (female) (1)
SEGR (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

SEGR (female) (3), (4)
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Ground fault in wiring harness SEGR (female) (1) and chassis ground
4
SEGR (female) (2) and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

SEGR (female) (3), (4) and chassis ground
Resistance
Min. 1 Mz

SEGR (female) (1) and between CE01
(female) (47) SEGR (female) (2)
34
Resistance
Min. 1 Mz

(female) (19) SEGR (female) (3), (4)
Resistance
Min. 1 Mz

(female) (19) SEGR (female) (3), (4)
Resistance
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Cause
Possible causes
and standard
value in normal
state
a

CE01
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR valve solenoid and lift sensor
PC400, 450-7E0
35
SEN03602-00
40 Troubleshooting
Failure code [CA2272] EGR Valve Lift Sens Low Error

Action code
Failure code
E11
CA2272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Lift Sens Low Error

Low error occurred in EGR valve lift sensor circuit.

Related
information
Possible causes
and standard
value in normal
state
36
Cause

PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03602-00
37
SEN03602-00
40 Troubleshooting
Failure code [CA2351] EGR Valve Sol Current High Error

Action code
Failure code
E11
CA2351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

High current error occurred in drive circuit of EGR valve solenoid.

Related
information
Cause
a
Defective EGR valve solenoid
1
(Internal defect)
EGR (male)
Resistance
Between (1) (2)
10 21 z

defective contact in connector) EGR (female) (1)
EGR (female) (2)
Possible causes
and standard
value in normal
state
a
3
Resistance
Max. 1 z
Resistance
Min. 1 Mz

EGR (female) (2) and chassis ground
Resistance
Min. 1 Mz


(Short circuit with 24V circuit) EGR (female) (1) and chassis ground
Voltage
Max. 1 V

EGR (female) (2) and chassis ground
Voltage
Max. 1 V
a
38
Max. 1 z
(Short circuit with GND circuit) EGR (female) (1) and chassis ground
a
4
Resistance
CE01 (female)
Resistance
Between (22) (11)
10 21 z
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to EGR valve solenoid and lift sensor
PC400, 450-7E0
39
SEN03602-00
40 Troubleshooting
Failure code [CA2352] EGR Valve Sol Current Low Error

Action code
Failure code
E11
CA2352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Low current error occurred in drive circuit of EGR valve solenoid.

Related
information
Possible causes
and standard
value in normal
state
40
Cause

PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action code
Failure code
E15
CA2555
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Voltage low error was detected in grid heater relay circuit.

None in particular.
Engine does not start easily at low temperature.
Related
information
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause

41
SEN03602-00
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error

Action code
Failure code
E15
CA2556
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Open error was detected in intake air heater relay circuit

None in particular.
Engine does not start easily at low temperature.
Heater relay drive conditions vary depending on applicable machine.
Cause
a
Defective grid heater relay
1
(Internal defect)
Possible causes
and standard
value in normal
state
R18 (male)
Resistance
Between (1) (2)
200 400 z

defective contact in connector) R18 (female) (1)
R18 (female) (2)
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z
(Short circuit with GND circuit) R18 (female) (1) and chassis ground
Resistance
Min. 1 Mz

R18 (female) (2) and chassis ground
Resistance
Min. 1 Mz
a

CE02
Between (40) (42)
42
Heater relay
Voltage
Operating condition
Max. 1 V
Stop condition
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to engine preheater
PC400, 450-7E0
43
SEN03602-00
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C

Action code
Failure code
D110KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

(Pump controller system)
Abnormal current flowed at output to battery relay drive circuit.

Turns output to battery relay drive circuit OFF.
Engine does not start.
Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
(Code 03700: Controller Output)
Cause
Possible causes
and standard
value in normal
state
Defective battery relay

Continuity/Resistance
Between R02 (terminal BR)

R01 (terminal E)
There is continuity
Between R02 (terminal BR)

chassis ground
Min. 1 Mz
a
2
Battery relay

(Short circuit with GND circuit) Wiring harness between CP03 (female) (4)
D01 J01 A02 R02 (terminal BR) and
chassis ground
a
3 Defective pump controller
44
Resistance
Min. 1 Mz

CP03
Turn starting switch

OFF.
Voltage
Between (4)
chassis ground
ON o OFF
20 30 V
(4 7 sec.)
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to battery relay drive
PC400, 450-7E0
45
SEN03602-00
40 Troubleshooting
Failure code [D196KA] Service Return Relay Disc.

Action code
Failure code
D196KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

When service return relay circuit was disconnected with GND (when output was turned OFF), 24V
was not generated.
None in particular.
Hydraulic circuit for attachment does not change to single operation circuit.
This code-related troubleshooting is done only when ATT is provided.
(Confirm settings on the machine monitor.)
Related
information
This code detects only a trouble in the primary side (coil side) of service return relay.
When service return solenoid may be in defective operation, check the power source,
wiring harness, and solenoid in the secondary side (contact side) of the relay.
Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
(Code 02301: Solenoid 2)
Cause
1 Defective fuse No.2

If fuse is burnt, circuit probably has ground fault.
a
2
Defective service return relay

Possible causes
and standard
value in normal
state
R20 (male)
Resistance
Between (1) (2)
100 500 z

Wiring harness between CP02 (female) (8)
R20 (female) (2)
Wiring harness between R20 (female) (1)
J03 F01-2 outlet
a
4

J03 F01-2 outlet and chassis ground
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

CP02

Between (8)
chassis ground
46
Max. 1 z
Ground fault in wiring harness Wiring harness between CP02 (female) (8)
(Short circuit with GND circuit) R20 (female) (2) and chassis ground
Resistance
Working mode
Voltage
When B-mode is not

selected
20 30 V
When B-mode is
selected
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-7E0
47
SEN03602-00
40 Troubleshooting
Failure code [D196KB] Service Return Relay S/C

Action code
Failure code
D196KB
Trouble

Contents of
trouble
When service return relay circuit was connected to GND (when output was turned ON), abnormal
current flowed.
Action of
controller
Turns output to service return relay circuit OFF.

Problem that
appears on
machine
Related
information
Hydraulic circuit for attachment does not change to single operation circuit.
This code-related troubleshooting is done only when ATT is provided. (Confirm settings on the
machine monitor.)
a This code detects only a trouble in the primary side (coil side) of service return relay.
When service return solenoid may be in defective operation, check the power source, wiring harness, and solenoid in the secondary side (contact side) of the relay.
Operating condition of service return relay (ON/OFF) can be checked with monitoring function.
Cause
a
1
Defective service return relay

(internal short circuit)
a
Possible causes
and standard
value in normal
state
R20 (male)
Resistance
Between (1) (2)
100 500 z

2
24V circuit) in wiring harness Wiring harness between CP02 (female) (8)
Voltage
a

CP02

Between (8)
chassis ground
48
Max. 1 V
Working mode
Voltage
When B-mode is not

selected
20 30 V
When B-mode is
selected
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-7E0
49
SEN03602-00
40 Troubleshooting
Failure code [DA25KP] Press. Sensor Power Abnormality

Action code
Failure code
E02
DA25KP
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Press. Sensor Power Abnormality

Abnormal current flowed in pressure sensor power supply (5V) circuit.

Turns output to power supply (5V) circuit OFF.
Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned
OFF.
Signal of pressure sensor is not input normally.
Pressure sensor failure code is displayed at the same time.
Related
information
Cause
Defective pressure sensor

Disconnect sensors
defective.
a
Possible causes
and standard
value in normal
state
F pump pressure
sensor
P25 connector
R pump pressure
sensor
P26 connector
Bucket CURL press

sensor
P01 connector
Arm IN pressure
sensor
P04 connector

A03 P25 (female) (3) and chassis ground
[F pump pressure sensor system]
Resistance
Min. 1 Mz

Ground fault in wiring harness A03 P26 (female) (3) and chassis ground
2
(Short circuit with GND circuit) [R pump pressure sensor system]
Resistance
Min. 1 Mz

[Bucket CURL pressure sensor system]
Resistance
Min. 1 Mz

[Arm IN pressure sensor system]
Resistance
Min. 1 Mz
a
50
Disconnect connector with starting switch OFF, then turn

starting switch ON and carry out troubleshooting.

CP01
Voltage
Between (22) (10)
4.5 5.5 V
PC400, 450-7E0
40 Troubleshooting
SEN03602-00
Circuit diagram related to pressure sensor power supply of pump controller
PC400, 450-7E0
51
SEN03602-00
40 Troubleshooting
Failure code [DA80MA] Auto. Lub. Abnormal.

a
52
This failure code is displayed only when automatic lubrication equipment is installed.
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03602-00
53
SEN03602-00

2008 KOMATSU
All Rights Reserved
54
SEN03603-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting

Failure code [DA2RMC] Pump Comm. Abnormality ....................................................................................... 4
Failure code [DA2SKQ] Model Selection Abnormality .................................................................................... 6
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................................... 8
Failure code [DHPAMA] F Pump P. Sensor Abnormality .............................................................................. 10
Failure code [DHPBMA] R Pump P. Sensor Abnormality.............................................................................. 12
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality ............................................................................ 14
Failure code [DHS4MA] Bucket Curl PPC Sen. Abnormality........................................................................ 16
Failure code [DW43KA] Travel Speed Sol. Disc. .......................................................................................... 18
Failure code [DW43KB] Travel Speed Sol. S/C ............................................................................................ 20
Failure code [DW45KA] Swing Brake Sol. Disc. ........................................................................................... 22
Failure code [DW45KB] Swing Brake Sol. S/C ............................................................................................. 26
Failure code [DW91KA] Travel Junction Sol. Disc. ....................................................................................... 28
Failure code [DW91KB] Travel Junction Sol. S/C ......................................................................................... 30
Failure code [DWJ0KA] Merge-divider Sol. Disc. ......................................................................................... 32
PC400, 450-7E0
SEN03603-00
40 Troubleshooting
Failure code [DWJ0KB] Merge-Divider Sol. S/C ........................................................................................... 34

Failure code [DWK0KA] 2-stage Relief Sol. Disc. ......................................................................................... 36
Failure code [DWK0KB] 2-stage Relief Sol. S/C........................................................................................... 38
Failure code [DXA0KA] PC-EPC Sol. Disc. .................................................................................................. 40
Failure code [DXA0KB] PC-EPC Sol. S/C .................................................................................................... 42
Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................................... 44
Failure code [DXE0KB] LS-EPC Sol. S/C ..................................................................................................... 46
Failure code [DXE4KA] Service Current EPC Disc....................................................................................... 48
Failure code [DXE4KB] Service Current EPC S/C........................................................................................ 49
Failure code [DY20KA] Wiper Working Abnormality ..................................................................................... 50
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................................... 52
Failure code [DY2CKB] Washer Drive S/C ................................................................................................... 54
Failure code [DY2DKB] Wiper Drive (For) S/C ............................................................................................. 56
Failure code [DY2EKB] Wiper Drive (Rev) S/C............................................................................................. 58
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03603-00
SEN03603-00
40 Troubleshooting
Failure code [DA2RMC] Pump Comm. Abnormality

Action code
Failure code
E0E
Contents of
trouble
Action of
controller
Problem that
appears on
machine
DA2RMC
Trouble

Pump controller detected communication error in CAN communication circuit between machine monitor and engine controller.
Fix engine output to E-mode, and limit pump absorption torque to about 80%.
Output lowers. (Pump absorption torque decreases.)
As the working load increases, engine may stall.
Related
information
Cause

defective contact in connector) CE02 (female) (47), CP02 (female) (22)
Max. 1 z
Resistance
Max. 1 z

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state


Hot short (Short circuit with CE02 (female) (47), CP02 (female) (22),
3
24V circuit) in wiring harness other related circuit and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
a
4

resistance

controller
Resistance
K02 (male), K31 (male)
Resistance
Between (A) (B)
120 12 z

or pump controller may be defective.
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to CAN communication of pump controller
PC400, 450-7E0
SEN03603-00
40 Troubleshooting
Failure code [DA2SKQ] Model Selection Abnormality

Action code
Failure code
DA2SKQ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Model code signal for model which is not registered in controller is input.
Changes input model code to code of default model (PC400) and continues control.
None in particular.
Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Input of model selection signal (ON/OFF) can be checked with monitoring function.
(Code 02200: Switch Input 2)
Cause
a
Defective model selection
connector
1
(Internal disconnection or
short circuit)
S30 (female)
Resistance
Between (2), (3), (7) (8)
Max. 1 z
Between (1), (4), (5), (6) (8)
Min. 1 Mz

S30 (male) (4) and chassis ground
Resistance
Max. 1 z

Disconnection in wiring harness S30 (male) (3)
defective contact in connector) Wiring harness between CP02 (female) (27)
S30 (male) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

S30 (male) (7)
Resistance
Max. 1 z
Wiring harness between S30 (male) (8)

J05 A01 chassis ground
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz
(Short circuit with GND circuit) S30 (male) (7) and chassis ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
aPrepare with starting switch OFF, then turn starting switch ON and
CP02
Voltage
Between (7), (37) chassis

ground
20 30 V
Between (13), (17), (27)

chassis ground
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to model selection connector of pump controller
PC400, 450-7E0
SEN03603-00
40 Troubleshooting
Failure code [DAFRMC] Monitor Comm. Abnormality

Action code
Failure code
E0E
DAFRMC
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble

Machine monitor detected communication error in CAN communication circuit between pump controller and engine controller.
Fix engine output to E-mode, and limit pump absorption torque to about 80%.
Output lowers. (Pump absorption torque decreases.)
As the working load increases, engine may stall.
Related
information
Cause

defective contact in connector) CE02 (female) (47), CP02 (female) (22)
Wiring harnesses between P70 (female) (15)
CE02 (male)(46) and CP02 (females) (32)
Max. 1 z
Resistance
Max. 1 z

2
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state
Hot short (Short circuit with CE02 (female) (47), CP02 (female) (22),
3
24V circuit) in wiring harness other related circuit and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
a
4

resistance

controller
Resistance
K02(male), K31(male)
Resistance
Between (A) (B)
120 12 z

or pump controller may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to CAN communication of machine monitor
PC400, 450-7E0
SEN03603-00
40 Troubleshooting
Failure code [DHPAMA] F Pump P. Sensor Abnormality

Action code
Failure code
DHPAMA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
No automatic gear shifting
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure
sensor will be broken. Accordingly, take extreme care when checking.
Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure)
Cause
1
Defective sensor power sup- If error code [DA25KP] is also displayed, carry out troubleshooting
ply system
for it first.
a
Defective F pump pressure
2 sensor
(Internal defect)
Possible causes
and standard
value in normal
state

P25
Voltage
Between (3) (1)
4.5 5.5V
Between (2) (1)
0.5 4.5V

Disconnection in wiring harness A03 P25 (female) (3)
A06 P25 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

Resistance
Max. 1 z

4
ResisA06 P25 (female) (2) and chassis ground
tance
Min. 1 Mz
5
Hot short (Short circuit with Wiring harness between CP01 (female) (22)
24V circuit) in wiring harness A03 P25 (female) (3) and chassis ground
Voltage
Max. 1 V

Voltage
Max. 1 V
a
10

CP01
Voltage
Between (22) (10)
4.5 5.5V
Between (8) (10)
0.5 4.5V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to F pump pressure sensor of pump controller
PC400, 450-7E0
11
SEN03603-00
40 Troubleshooting
Failure code [DHPBMA] R Pump P. Sensor Abnormality

Action code
Failure code
DHPBMA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure
Cause
1
ply system
for it first.
a
Defective R pump pressure
2 sensor
(Internal defect)
Possible causes
and standard
value in normal
state

P26
Voltage
Between (3) (1)
4.5 5.5V
Between (2) (1)
0.5 4.5V

Resistance
Max. 1 z
Resistance
Max. 1 z

Resistance
Max. 1 z

4
ResisA06 P26 (female) (2) and chassis ground
tance
Min. 1 Mz
5
Voltage
Max. 1 V

Voltage
Max. 1 V
a
12

CP01
Voltage
Between (22) (10)
4.5 5.5V
Between (2) (10)
0.5 4.5V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to R pump pressure sensor of pump controller
PC400, 450-7E0
13
SEN03603-00
40 Troubleshooting
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality

Action code
Failure code
DHS3MA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage from arm curl PPC pressure sensor is below 0.3 V or above 4.72 V.
Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm Curl PPC Pressure
Cause
1
ply system
for it first.
a
2
Defective arm curl PPC pressure sensor (Internal defect)
Possible causes
and standard
value in normal
state

P04
Voltage
Between (3) (1)
4.5 5.5V
Between (2) (1)
0.5 4.5V

Resistance
Max. 1 z
Resistance
Max. 1 z

P04 (female) (2)
Resistance
Max. 1 z
Ground fault in wiring harshooting without turning starting switch ON.

4 ness
Resis(Short circuit with GND circuit) Wiring harness between CP01 (female) (19)
tance
a
5
Min. 1 Mz

Voltage
Max. 1 V

Voltage
Max. 1 V
a
14

CP01
Voltage
Between (22) (10)
4.5 5.5V
Between (19) (10)
0.5 4.5V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to arm curl PPC pressure sensor of pump controller
PC400, 450-7E0
15
SEN03603-00
40 Troubleshooting
Failure code [DHS4MA] Bucket Curl PPC Sen. Abnormality

Action code
Failure code
DHS4MA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
aIf 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure
Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC Pressure)
Cause
1
ply system
for it first.
a
Defective bucket curl PPC
2 pressure sensor (Internal
defect)
Possible causes
and standard
value in normal
state

P01
Voltage
Between (3) (1)
4.5 5.5V
Between (2) (1)
0.5 4.5V

Resistance
Max. 1 z
Resistance
Max. 1 z

P01 (female) (2)
Resistance
Max. 1 z

4
ResisP01 (female) (2) and chassis ground
tance
a
5
Min. 1 Mz

Voltage
Max. 1 V

Voltage
Max. 1 V
a
16

CP01
Voltage
Between (22) (10)
4.5 5.5V
Between (13) (10)
0.5 4.5V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC400, 450-7E0
17
SEN03603-00
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol. Disc.

Action code
Failure code
DW43KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

No current flows travel speed solenoid circuit as power is turned on.

None in particular. (Since no current flows, solenoid does not operate.)
Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be
sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for
failure code [DW43KB].)
Cause
a
1

a
Possible causes
and standard
value in normal
state
V04 (male)
Resistance
Between (1) (2)
20 60 z

defective contact in connector) A05 V04 (female) (2)
Wiring harness between V04 (female) (1)
chassis ground
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z


A05 V04 (female) (2) and chassis ground
18
Voltage
Max. 1 V
CP03 (female)
Resistance
20 60 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-7E0
19
SEN03603-00
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol. S/C

Action code
Failure code
DW43KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Abnormal current flowed at output to travel speed solenoid circuit.

Turns output to travel speed solenoid circuit OFF.
Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
Cause
a
1 (Internal short circuit or
ground fault)
Possible causes
and standard
value in normal
state
V04 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz

2
ResisA05 V04 (female) (2) and chassis ground
tance
a
20
Min. 1 Mz

CP03
Travel speed
Voltage
Between (27)
chassis ground
Lo
Max. 1 V
Hi + Travel operation
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-7E0
21
SEN03603-00
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol. Disc.

Action code
Failure code
E03
DW45KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

No current flows at output to swing brake solenoid circuit.

Machine cannot swing.
Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing brake
release switch in release position (Swing holding brake does not work, however, when machine stops).
Turn both of swing lock and emergency swing release switches OFF during troubleshooting.
Cause
Defective swing holding
1 brake solenoid (Internal disconnection)
a
2
Defective swing lock switch

V05 (male)
Resistance
Between (1) (2)
20 60 z
S04 (female)
Between (3) (4)
Possible causes
and standard
value in normal
state
Defective assembled-type
3 diode D01
Switch
Resistance
OFF
Max. 1 z
LOCK
Min. 1 Mz
D01 (male)
Digital circuit tester
Continuity
Between (7) (3)
Diode mode
There is continuity

D01 (female) (7)
Resistance
Max. 1 z

Wiring harness between D01 (female) (3)
J02 S04 (male) (3)
A05 V05 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

CP03 (female) (3), (13), (23)
Resistance
Max. 1 z
5
22
24V circuit) in wiring harness D01 H06 S04 (male) (3) and chassis ground
Voltage
Max. 1 V
Wiring harness between V05 (female) (2) A05

H06 S04 (male) (4) and chassis ground
Voltage
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Cause
Possible causes
and standard
value in normal
state
PC400, 450-7E0
a
CP03 (female)
Between (37)
chassis ground
Disconnect D01 and

connect pins (3) and (7)
on female side directly.
Resistance
20 60 z
23
SEN03603-00
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid of pump controller
24
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03603-00
25
SEN03603-00
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol. S/C

Action code
Failure code
E03
DW45KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Abnormal current flowed at output to swing brake solenoid circuit.

Turns output to swing brake solenoid circuit OFF.
Machine cannot swing.
Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
If solenoid and wiring harness are normal, operator can swing machine by setting emergency swing
brake release switch to release position (Swing holding brake does not work, however, when machine stops).
Cause
a
Defective swing holding
1 brake solenoid (Internal short
circuit or ground fault)
2 diode D01
Possible causes
and standard
value in normal
state
V05 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz
D01 (male)
Resistance
Between (3) (7)
Min. 1 Mz
(Short circuit with GND circuit) D01 J02 H06 S04 (male) (3) and chassis ground
Resistance
Min. 1 Mz
Wiring harness between V05 (female) (2) A05

H06 S04 (male) (4) and chassis ground
Resistance
Min. 1 Mz
a
26

CP03
Swing lever
Voltage
Between (37)
chassis ground
When at neutral
Max. 1 V
At swing
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to swing holding brake solenoid of pump controller
PC400, 450-7E0
27
SEN03603-00
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol. Disc.

Action code
Failure code
DW91KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

No current flows at output to travel junction valve solenoid circuit.

Turning from operating travel steering becomes difficult.
Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Cause
Defective travel junction
1 solenoid
Possible causes
and standard
value in normal
state
V02 (male)
Resistance
Between (1) (2)
20 60 z
Disconnection in wiring harness Wiring harness between CP03 (female) (7)

A05 CP03 (female) (3), (13),
(23) chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
Voltage Max. 1 V
a
28
CP03 (female)
Resistance
Between (7) (3), (13), (23)
20 60 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-7E0
29
SEN03603-00
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol. S/C

Action code
Failure code
DW91KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Abnormal current flowed at output to travel junction solenoid circuit.

Turns output to travel junction solenoid OFF.
Hard to turn when operating travel steering.
Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Cause
a
Defective travel junction
solenoid
1
(Internal short circuit or
ground fault)
Possible causes
and standard
value in normal
state
V02 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz

2
tance
a
30
Min. 1 Mz

CP03
Travel lever
Voltage
Between (7) (3),

(13), (23)
At straight advance
Max. 1 V
At steering
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-7E0
31
SEN03603-00
40 Troubleshooting
Failure code [DWJ0KA] Merge-divider Sol. Disc.

Action code
Failure code
DWJ0KA
Contents of
trouble
Action of
controller
Trouble
Merge-divider Sol. Disc.

No current flows at output to merge-divider solenoid circuit.

Problem that
appears on
machine
Independent operation speed of work equipment and swing machinery is re high in lifting mode (L).
Related
information
Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Solenoid detects disconnection when output is turned on. To confirm the modification after repair, be
failure code [DWJ0KB].)
Cause
Defective merge-divider
1 solenoid
Possible causes
and standard
value in normal
state
V03 (male)
Resistance
Between (1) (2)
20 60 z
Disconnection in wiring harness Wiring harness between CP03 (female) (17)

A05 CP03 (female) (3), (13), (23) chassis
ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with carry out troubleshooting.
3
Voltage Max. 1 V
a
32
CP03 (female)
Resistance
Between (17) (3), (13), (23)
20 60 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to merge-divider solenoid of pump controller
PC400, 450-7E0
33
SEN03603-00
40 Troubleshooting
Failure code [DWJ0KB] Merge-Divider Sol. S/C

Action code
Failure code
DWJ0KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Merge-Divider Sol. S/C

Abnormal current flowed at output to merge-divider solenoid circuit.

Turns output to merge-divider solenoid circuit OFF.
Single operation speed of work equipment and swing is re high in lifting mode (L).
Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Cause
a
Defective merge-divider
solenoid
1
ground fault)
Possible causes
and standard
value in normal
state
V03 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz

2
tance
a
Min. 1 Mz

CP03
Between (17) (3),

(13), (23)
34
Travel lever
Voltage
When at neutral
Max. 1 V
When either side is

operated
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to merge-divider solenoid of pump controller
PC400, 450-7E0
35
SEN03603-00
40 Troubleshooting
Failure code [DWK0KA] 2-stage Relief Sol. Disc.

Action code
Failure code
DWK0KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

No current flows at output to 2-stage relief solenoid circuit.

Power maximizing function does not work.
Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
failure code [DWK0KB].)
Cause
Defective 2-stage relief sole1 noid
a
Possible causes
and standard
value in normal
state
V08 (male)
Resistance
Between (1) (2)
20 60 z

defective contact in connector) A05 V08 (female) (2)
A05 CP03 (female) (3), (13), (23)
a
3
Resistance
Max. 1 z
Resistance
Max. 1 z

Hot short (short circuit with

36
Voltage
Max. 1 V
CP03 (female)
Resistance
20 60 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400, 450-7E0
37
SEN03603-00
40 Troubleshooting
Failure code [DWK0KB] 2-stage Relief Sol. S/C

Action code
Failure code
DWK0KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Abnormal current flowed at output to 2-stage relief solenoid circuit.

Turns output to 2-stage relief solenoid circuit OFF.
Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Cause
a
Defective 2-stage relief solenoid
1
ground fault)
Possible causes
and standard
value in normal
state
V08 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz

2
tance
a
Min. 1 Mz

CP03
Between (28)
chassis ground
38
Working mode
Voltage
When L-mode is not

selected
Max. 1 V
L-mode is selected
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400, 450-7E0
39
SEN03603-00
40 Troubleshooting
Failure code [DXA0KA] PC-EPC Sol. Disc.

Action code
Failure code
E02
DXA0KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
PC-EPC Sol. Disc.

No current flows at output to PC-EPC solenoid circuit.

If pump load increases, engine speed lowers largely and engine may stall.
Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)
Cause
a
1
Defective PC-EPC solenoid

a
Defective emergency pump
2 drive switch (Internal disconnection)
V11 (male)
Resistance
Between (1) (2)
7 14 z
S21
Between (2) (3)

Between (5) (6)
a
Possible causes
and standard
value in normal
state
Switch
Resistance
OFF
Max. 1 z
ON
Min. 1 Mz
OFF
Max. 1 z
ON
Min. 1 Mz

S21 (3)

Wiring harness between S21 (2) V11
defective contact in connector) (female) (1)
Wiring harness between CP03 (female) (21),
(32), (33) J05 chassis ground
(female) (2)
a
4

(female) (1) and chassis ground
40
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Hot short (short circuit with

24V circuit) in wiring harness S21 (3) and chassis ground
Resistance
Voltage
Max. 1 V
Voltage
Max. 1 V
CP03 (female)
Resistance
Between (16) (21), (32), (33)
7 14 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC400, 450-7E0
41
SEN03603-00
40 Troubleshooting
Failure code [DXA0KB] PC-EPC Sol. S/C

Action code
Failure code
E02
DXA0KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
PC-EPC Sol. S/C

Abnormal current flowed at output to PC-EPC solenoid circuit.

Turns output to PC-EPC solenoid circuit OFF.
If pump load increases, engine speed lowers largely and engine may stall.
Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)
aTurn the emergency pump drive switch off as long as troubleshooting is continued.
Cause
a
Defective PC-EPC solenoid
ground fault)
Possible causes
and standard
value in normal
state
V11 (male)
Resistance
Between (1) (2)
7 14 z
Min. 1 Mz

2
ResisS21 V11 (female) (1) and chassis ground
tance
a
42
Min. 1 Mz
CP03 (female)
Resistance
Between (16) (21), (32), (33)
7 14 z
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
43
SEN03603-00
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol. Disc.

Action code
Failure code
DXE0KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
LS-EPC Sol. Disc.

No current flows at output to LS-EPC solenoid circuit.

Travel speed Mi or Lo is high.
Work equipment speed and swing speed are high in lifting mode (L).
Output to LS-EPC solenoid (current value) can be checked with monitoring function.
(Code 01500: LS-EPC Sol. Curr.)
Cause
a
Defective LS-EPC solenoid
1
Possible causes
and standard
value in normal
state
V19 (male)
Resistance
Between (1) (2)
7 14 z

Disconnection in wiring harness A04 V19 (female) (1)
defective contact in connector) Wiring harness between CP03 (female) (21),
(32), (33) J05 chassis ground
(female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage
a
44
Max. 1 V
CP03 (female)
Resistance
Between (6) (21), (32), (33)
7 14 z
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
45
SEN03603-00
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol. S/C

Action code
Failure code
DXE0KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
LS-EPC Sol. S/C

Abnormal current flowed at output to LS-EPC solenoid circuit.

Turns output to LS-EPC solenoid circuit OFF.
Travel speed Mi or Lo is high.
Work equipment speed and swing speed are high in lifting mode (L).
Output to LS-EPC solenoid (current value) can be checked with monitoring function.
(Code 01500: LS-EPC Sol. Curr.)
Cause
a
Defective LS-EPC solenoid
ground fault)
Possible causes
and standard
value in normal
state
V19 (male)
Resistance
Between (1) (2)
7 14 z
Min. 1 Mz

2
tance
a
46
Min. 1 Mz
CP03 (female)
Resistance
Between (6) (21), (32), (33)
7 14 z
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
47
SEN03603-00
40 Troubleshooting
Failure code [DXE4KA] Service Current EPC Disc.

Action code
Failure code
DXE4KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

No current flows at output to service current EPC solenoid circuit.

Attachment does not move.
Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Output to service current EPC solenoid (current value) can be checked with monitoring function.
(Code 01700: Service Sol. Curr.)
Cause
Defective service current
1 EPC solenoid (Internal disconnection)
a
Possible causes
and standard
value in normal
state
V30 (male)
Resistance
Between (1) (2)
7 14 z

defective contact in connector) V30 (female) (1)
Wiring harness between CP03 (female) (3),
(13), (23) V30 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Voltage
V30 (female) (1) and chassis ground
a
Max. 1 V
CP03 (female)
Resistance
Between (26) (3), (13), (23)
7 14 z
Circuit diagram related to service current EPC solenoid of pump controller
48
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Failure code [DXE4KB] Service Current EPC S/C

Action code
Failure code
DXE4KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Abnormal current flowed at output to service current EPC solenoid circuit.

Turns output to service current EPC solenoid circuit OFF.
Attachment does not move.
This code-related troubleshooting is done only when ATT is provided. (Confirm settings on the
machine monitor.)
Output to service current EPC solenoid (current value) can be checked with monitoring function.
(Code 01700: Service Sol. Curr.)
Cause
a
Defective service current
1 EPC solenoid (Internal short
circuit or ground fault)
Possible causes
and standard
value in normal
state
V30 (male)
Between (1) (2)
7 14 z
Min. 1 Mz

V30 (female) (1) and chassis ground
a
Resistance
a
2
Resistance
Min. 1 Mz
CP03 (female)
Resistance
Between (26) (3), (13), (23)
7 14 z
Min. 1 Mz
Circuit diagram related to service current EPC solenoid of pump controller
PC400, 450-7E0
49
SEN03603-00
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality

Action code
Failure code
DY20KA
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble

When windshield wiper works, W signal of working ends is not input.

Turns working output to wiper motor OFF.
Windshield wiper does not operate.

Input of W signal in wiper working area (ON/OFF) can be checked with monitoring function.
(Code 04502 Monitor Input 3)
Cause
a
1
W04 (male)
Defective wiper motor

Between (6) (5)
Possible causes
and standard
value in normal
state
Wiper blade
Resistance
Upper operating limit
Max. 1 z
Other than upper

operating limit
Min. 1 Mz

defective contact in connector) W04 (female) (6)
Wiring harness between W04 (female) (5)
chassis ground
a
Resistance
Max. 1 z
Resistance
Max. 1 z

P01
Between (5)
chassis ground
50
Wiper blade
Voltage
Upper operating limit
Max. 1 V
Other than upper

operating limit
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to wiper motor of machine monitor
PC400, 450-7E0
51
SEN03603-00
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality

Action code
Failure code
DY20MA
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Related
information
Trouble

When parking windshield wiper, P signal for storage area is not input.
Turns parking output to wiper motor OFF.
Windshield wiper does not park.

Input of P signal for wiper parking area (ON/OFF) can be checked with monitoring function.
(Code 04502 Monitor Input 3)
Cause
a
1

W04 (male)
Between (4) (5)

Possible causes
and standard
value in normal
state
Wiper blade
Resistance
Storage area
Max. 1 z
Working area
Min. 1 Mz

defective contact in connector) W04 (female) (4)
Wiring harness between W04 (female) (5)
chassis ground
a
52
Resistance
Max. 1 z
Resistance
Max. 1 z

P01
Wiper blade
Voltage
Between (12)
chassis ground
Storage area
Max. 1 V
Working area
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
53
SEN03603-00
40 Troubleshooting
Failure code [DY2CKB] Washer Drive S/C

Action code
Failure code
DY2CKB
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Trouble
Washer Drive S/C

When washer drive circuit was connected to GND (when output was turned ON), abnormal current
flowed.
Turns output to washer motor circuit OFF.
Window washer operation stops.
Related
information
Cause
a
1
Possible causes
and standard
value in normal
state
Defective washer motor

a
2
M06 (male)
Resistance
Between (1) (2)
5 20 z


24V circuit) in wiring harness Wiring harnesses between P01 (female) (3)
J04 M06 (female) (2), D02 (female) (8)
and chassis ground
a
54
Voltage
Max. 1 V

P01
Washer switch
Voltage
Between (3)
chassis ground
OFF
20 30 V
ON
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
Circuit diagram related to window washer motor of machine monitor
PC400, 450-7E0
55
SEN03603-00
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (For) S/C

Action code
Failure code
DY2DKB
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Trouble
Wiper Drive (For) S/C

Abnormal current flowed at output to wiper motor drive (for) circuit.

Turns output to wiper motor drive (for) circuit OFF.
Wiper operation stops.
Related
information
Cause
a
ground fault)
Possible causes
and standard
value in normal
state
W04 (male)
Between (3) (1)
There is continuity
Min. 1 Mz

2
ResisW04 (female) (3) and chassis ground
tance
a

P01
Between (9)
chassis ground
56
Min. 1 Mz
Wiper switch
Voltage
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(Constant cycle)
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
57
SEN03603-00
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) S/C

Action code
Failure code
DY2EKB
Contents of
trouble
Action of
machine
monitor
Problem that
appears on
machine
Trouble
Wiper Drive (Rev) S/C

Abnormal current flowed at output to wiper motor drive (rev.) circuit.

Turns output to wiper motor drive (rev.) circuit OFF.
Wiper operation stops.
Related
information
Cause
a
ground fault)
Possible causes
and standard
value in normal
state
W04 (male)
Between (1) (3)
There is continuity
Min. 1 Mz

2
ResisW04 (female) (1) and chassis ground
tance
a

P01
Between (10)
chassis ground
58
Min. 1 Mz
Wiper switch
Voltage
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(Constant cycle)
PC400, 450-7E0
40 Troubleshooting
SEN03603-00
PC400, 450-7E0
59
SEN03603-00

2008 KOMATSU
All Rights Reserved
60
SEN03604-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting
Troubleshooting of electrical system

(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 4
Information contained in troubleshooting table ............................................................................................... 6
E-1 Engine does not start ............................................................................................................................... 7
E-2 Auto-decelerator does not operate......................................................................................................... 10
E-3 Automatic warming-up does not operate................................................................................................ 12
E-4 Preheater does not operate.................................................................................................................... 14
E-5 All work equipment, swing, and travel mechanism do not move............................................................ 16
E-6 Power maximizing function does not operate......................................................................................... 18
E-7 Machine monitor does not display at all ................................................................................................. 20
E-8 Machine monitor does not display some items ...................................................................................... 22
E-9 Contents of display by machine monitor are different from applicable machine .................................... 22
E-10 Fuel level monitor was lighted in red while engine running .................................................................. 23
E-11 Engine coolant temperature gauge does not indicate normally............................................................ 24
E-12 Hydraulic oil temperature gauge does not indicate normally................................................................ 26
PC400, 450-7E0
SEN03604-00
40 Troubleshooting
E-13 Fuel level gauge does not operate normally......................................................................................... 27

E-14 Swing lock monitor does not indicate normally..................................................................................... 28
E-15 When monitor switch is operated, monitor displays nothing................................................................. 30
E-16 Windowshield wiper does not operate.................................................................................................. 32
E-17 Machine push-up function does not operate normally.......................................................................... 36
E-18 Monitoring function fails to display boom RAISE normally................................................................. 38
E-19 Monitoring function fails to display boom LOWER normally .............................................................. 40
E-20 Monitoring function fails to display arm INnormally............................................................................ 42
E-21 Monitoring function fails to display arm OUT normally....................................................................... 44
E-22 Monitoring function fails to display bucket CURLnormally ................................................................. 46
E-23 Monitoring function fails to display bucket DUMP normally ............................................................... 48
E-24 Monitoring function fails to display swing normally ............................................................................ 50
E-25 Monitoring function fails to display travel normally............................................................................. 52
E-26 Monitoring function fails to display travel differential pressure normally ............................................ 54
E-27 Monitoring function fails to display service normally .......................................................................... 56
E-28 The KOMTRAX system does not operate normally.............................................................................. 58
E-29 Air conditioner does not operate........................................................................................................... 60
E-30 Travel alarm does not sound or does not stop sounding...................................................................... 62
E-31 Horn does not sound ............................................................................................................................ 64
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
SEN03604-00
40 Troubleshooting
Before carrying out troubleshooting of electrical system
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see if the power is supplied normally.
Types of
Fusible link
power supply
Fuse No.
Fuse capacity
Destination of power
10A
Pump controller
20A
Pump controller (Solenoid power supply)
20A

Switch power
supply
Switch power
supply
Switch power
supply
Constant
power supply
F04
(65A)
F04
(65A)
F04
(65A)
F05
(30A)
Switch power
Starting
supply
switch ACC
Machine monitor
Wiper drive
Cigarette lighter
10A
10A
Horn relay, horn
10A
Electrical intake air heater relay
10A
Rotary lamp (If equipped)
10A
Relay for lamp
10A
10
10A
11
20A
12
20A
(Spare)
13
20A
Lamp, lamp relay drive
14
10A
15
10A
16
10A
17
10A
18
10A
(Spare)
19
30A
Engine controller
20
5A
Engine controller (ACC signal)
Radio, Speaker
Left knob switch (pump controller input)
(Spare)
Travel alarm, 12 V power supply

Radio (backup power supply)
Room lamp
Starting switch
Machine monitor
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Locations of fusible links and fuse No.
PC400, 450-7E0
SEN03604-00
40 Troubleshooting
Information contained in troubleshooting table

a
Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure
phenomenon
Relative
information
Phenomenon occurring on machine

Information on the failure occurred as well as the troubleshooting
Cause
<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
Disconnection
Connector is connected imperfectly or wiring harness is broken.
Ground fault
Wiring harness which is not connected to chassis ground circuit is
in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source (24 V) circuit is in contact with power source (24 V) circuit.
2
Possible causes
and standard
value in normal
state
Possible causes of trouble

(Given numbers are reference numbers, which do
<Precautions for troubleshooting>
not indicate priority)
(1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
If connector No. has no marks of male and female, disconnect connector and insert T-adapters in both male side and
female side.
If connector No. has marks of male and female, disconnect
connector and connect T-adapter to only male side or female
side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as
explained below for troubleshooting, unless otherwise specified.
4
Connect positive (+) lead to pin No. or wiring harness entered
on front side.
Connect negative () lead to pin No. or harness entered on
rear side.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion
where the failure occurred.
Connector No.: Indicates (Type numbers of a pin) (color)
Arrow : Roughly indicates the location in the machine where it is
installed.
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
E-1 Engine does not start

Trouble
Related
information
Engine does not start (Engine does not turn).

Engine starting circuit has following 2 start lock mechanisms:
1) Start lock by the machine monitor password
2) Start lock by the safety lock lever
In the case no error code for the engine controller mechanism is indicated
Cause
1 Low charge level of battery
Battery voltage
Specific gravity of battery
Min. 24 V
Min. 1.26
If fuse or fusible link is burnt out, the circuit probably has ground fault.
Defective fuse No. 3, No. 17
2
In the case the machine monitor does not light up, check the power
or fusible link F04 and F05
circuit between the battery and the fuse.
a
3
Defective starting switch

H06 (male)
Between (1) (4)
a
Defective work equipment
4 lock switch (internal short circuit)
S14 (female)
a
Defective starting motor cutout relay R06 or R07 (inter5
nal disconnection or short
circuit)
Defective starting motor

6 (Internal disconnection or
breakage)
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
Between (1) (3)

Possible causes
and standard
value in normal
state
Position
Lock lever
Resistance
Free
Min. 1 Mz
Lock
Max. 1 z
R06 (male), R07 (male)
Resistance
Between (1) (2)
100 500 z
Between (3) (5)
Min. 1 Mz
Between (3) (6)
Max. 1 z

(If power supply and starting input and output are normal
but starting motor does not turn, starting motor is defective.)
Starting motor
Power supply: Between terminal

B chassis ground
Starting input: Between terminal C
chassis ground and chassis ground
a
7
PC400, 450-7E0
Defective alternator
Starting
switch
Voltage
20 30 V
START
20 30 V

Alternator
Voltage
Between terminal R
chassis ground
Max. 1 V
SEN03604-00
40 Troubleshooting
Cause
Wiring harness between F01-17 outlet H06

(female) (1)
Resistance
Max. 1 z
Wiring harness between H06 (female) (4)

J01 R06 (female) (5)
Resistance
Max. 1 z

M17 (female) (1)
defective contact in connector) Wiring harness between F01-3 outlet S14
(female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

R06 (female) (1)
Resistance
Max. 1 z

R07 (female) (6)
Resistance
Max. 1 z

J04 chassis ground
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state
10
Wiring harness between battery relay terminal B (R04) F05 F01-17D inlet and chassis ground
Resistance
Min. 1 Mz
Wiring harness between F01-17 outlet H06

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Wiring harness between F01-3 S14

Resistance
Min. 1 Mz
Wiring harness between S14 (female) (3)

Resistance
Min. 1 Mz

J05 P02 (female) (14) and chassis ground
Resistance
Min. 1 Mz

Ground fault in wiring harness J01 R06 (female) (5) and chassis ground
M17 (female) (1) and chassis ground


24V circuit) in wiring harness Wiring harness between P02 (female) (11)
J02 M17 (female) (2), D01 (female) (6),
alternator terminal R and chassis ground
Voltage
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to engine start and battery charging
PC400, 450-7E0
SEN03604-00
40 Troubleshooting
E-2 Auto-decelerator does not operate

Trouble
Related
information
Auto-decelerator does not operate.

Set speed of auto-decelerator is 1,400 rpm. Thus, the fuel control dial must be set above this speed
when operating the auto-decelerator.
Check all the monitoring indications after starting the engine.
Cause

In the case monitoring is not normally indicated, proceed to troubleshooting No. E-18.
1 Defective boom RAISE signal
Monitoring code
01900
Item
Normal display
Boom RAISE
Operation of lever:
ON
Lever in neutral: OFF
2 Defective boom LOWER signal
Monitoring code
Item
Normal display
01900
Boom LOWER
Operation of lever:
ON
3 Defective arm IN signal
Possible causes
and standard
value in normal
state
Monitoring code
01900
Item
Normal display
Arm IN
Operation of lever:
ON
4 Defective arm OUT signal
Monitoring code
Item
Normal display
01900
Arm OUT
Operation of lever:
ON
5
Defective bucket CURL signal
Monitoring code
01901
Item
Normal display
Bucket CURL
Operation of lever:
ON
6
10
Defective bucket DUMP signal
Monitoring code
Item
Normal display
01901
Bucket DUMP
Operation of lever:
ON
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Cause

7 Defective swing signal
Monitoring code
Item
Normal display
01900
Swing
Operation of lever:
ON
Possible causes
and standard
value in normal
state
8 Defective travel signal
Monitoring code
01900
Item
Normal display
Travel
Operation of lever:
ON
9 Defective attachment signal
PC400, 450-7E0
Monitoring code
Item
Normal display
01901
Service
Operation of lever:
ON

causes 1 9 above are not detected, engine controller may be
defective.)
11
SEN03604-00
40 Troubleshooting
E-3 Automatic warming-up does not operate

Trouble
Related
information
Automatic warming-up system does not operate

When engine coolant temperature is below 30C, automatic warm-up system raises engine speed to
1,250 rpm.
If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned
ON or after engine is started, automatic warm-up system is turned OFF.
Cause

Possible causes
and standard
value in normal
state

temperature signal
12
Monitoring code
Item
Normal display
04102
Engine coolant
temperature
Compare with actual

engine coolant
temperature
Since trouble is in system, troubleshooting cannot be carried out.

(If causes stated above are not detected, engine controller may be
defective.)
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
13
SEN03604-00
40 Troubleshooting
E-4 Preheater does not operate
Trouble (1)
When starting switch is turned to HEAT position, preheating monitor does not light up.
Related
information
Input of preheating signal (ON/OFF) can be checked with monitoring function.

Cause
Defective starting switch sys- If preheating fails to operate (the heater does not warm up), refer to
1
tem
Trouble (2)
Possible causes
and standard
value in normal
state

J02 (male) (7)
tance
a
Max. 1 z
Prepare with starting switch OFF

P02
Starting switch
Voltage
Between (18)
chassis ground
OFF
Max. 1 V
HEAT
20 30 V
Trouble (2)
When starting switch is turned to HEAT position, preheater does not warm up.
Related
information
During low temperature (coolant temperature below 30C), pump controller drives the heater relay
for 100 sec. after engine start to automatically preheat.
Cause
a
1

H06 (male)
Defective heater relay

Starting switch
Resistance
OFF
Min. 1 Mz
HEAT
Max. 1 z
Between (1) (3)
a
Possible causes
and standard
value in normal
state
Prepare with starting switch OFF
Heater relay
Resistance
Coil terminal chassis ground

Between contact terminals
Defective intake air heater

(Internal disconnection).
Between heater terminals
Min. 1 Mz
Normal if conductive

J02 Heater relay terminal R17
Wiring harness between battery relay terminal M (R03) Heater relay terminal R15
14
Resistance
Max. 1 z
Resistance
Max. 1 z
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to engine preheater
PC400, 450-7E0
15
SEN03604-00
40 Troubleshooting
E-5 All work equipment, swing, and travel mechanism do not move
Trouble
Related
information
All travel, swing, and work equipment mechanism do not move.
Cause

If fuse is burnt out, the circuit probably has ground fault.
a
2
Defective safety lock switch

(internal disconnection)
S14 (female)
Between (1) (2)
a
Defective PPC lock solenoid
short circuit)
Possible causes
and standard
value in normal
state
4 diode D01
Lock lever
Resistance
Lock
Min. 1 Mz
Free
Max. 1 z
V01 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz
D01 (male)
Resistance
Between (8) (4)
Min. 1 Mz
Wiring harness between F01-3 outlet J06

S14 (male) (1)
defective contact in connector) Wiring harness between S14 (male) (2)
J02 V01 (male) (2)
chassis ground
16
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

J02 V01(female) (2), D01(female) (8)
and chassis ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to PPC lock solenoid
PC400, 450-7E0
17
SEN03604-00
40 Troubleshooting
E-6 Power maximizing function does not operate

Trouble
Related
information

Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed
during work equipment operation while the engine is running in A- or E-mode.
Input state of power maximizing switch (left knob switch) can be checked with monitoring function
(Code 02200: Switch Input 1)
Cause

a
Defective power maximizing
2 switch (Internal disconnection)
S11(male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Switch
Resistance
Released
Min. 1 Mz
Pressed
Max. 1 z

Wiring harness between F01-9 outlet S11
(female) (1)
CP01 (female) (11)
a
4
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harness Wiring harness between F01-9 outlet S11
(Short circuit with GND circuit) (female) (1) and chassis ground
Resistance
Min. 1 Mz

CP01 (female) (11) and chassis ground
Resistance
Min. 1 Mz
a

CP01
Switch
Voltage
Between (11)
chassis ground
Released
Max. 1 V
Pressed
20 30 V
Circuit diagram related to power max. switch
18
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
19
SEN03604-00
40 Troubleshooting
E-7 Machine monitor does not display at all

Trouble
Related
information
Machine monitor does not display at all when starting switch is turned ON
Cause

a
2
Possible causes
and standard
value in normal
state
a
3

Wiring harness between P01(female) (1), (2)
defective contact in connector) J06 F01-3 outlet
Wiring harness between P01 (female) (6),
(7) chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

(Short circuit with GND circuit) Wiring harness between P01(female) (1), (2)
J06 F01-3 outlet and chassis ground
20
Resistance
Min. 1 Mz

P01 (female)
Voltage/Resistance
Between (1), (2)

chassis ground
Voltage: 20 30 V
Between (6), (7)

chassis ground
Resistance: Max. 1 z
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to power source in monitor panel
PC400, 450-7E0
21
SEN03604-00
40 Troubleshooting
E-8 Machine monitor does not display some items

Trouble
Related
information
Machine monitor does not display some items when starting switch is turned ON
Cause
Possible causes
and standard
value in normal
state
Defective machine monitor

LCD
When following switches are operated, if all LCD panel is lighted up

(all surface becomes white), LCD panel is normal.
Switch operation: [ ] + [A] (Simultaneous operation)

causes stated above are not detected, engine controller may be
defective.)
E-9 Contents of display by machine monitor are different from

applicable machine
Trouble
Related
information
Contents of display by machine monitor are different from applicable machine.
Cause

In the case monitoring display is not normal, proceed to failure code
code [DA2SKQ].
Possible causes
and standard
value in normal
state
Defective model code signal

(Internal defect)
00200
00201
22
Monitoring code
Item
Controller model
code
Select model
Normal display
300

(If causes stated above are not detected, engine controller may be
defective.)
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
E-10 Fuel level monitor was lighted in red while engine running
Trouble
Related
information
Fuel level monitor was lighted in red while the engine running
If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
(Code 04200: Fuel Level Sensor Vol.)
Cause
1
2
Possible causes
and standard
value in normal
state
Low fuel level

(When system is normal)
Add fuel
Defective fuel level sensor

P21 (male)
Fuel level
Resistance
Between (1)
chassis ground
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z

P21 (female) (1)
tance
a
Max. 1 z
P02 (female)
Fuel level
Resistance
Between (2)
chassis ground
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Circuit diagram related to fuel level sensor
PC400, 450-7E0
23
SEN03604-00
40 Troubleshooting
E-11 Engine coolant temperature gauge does not indicate normally

Trouble
Related
information
While engine coolant temperature is rising normally, temperature gauge does not rise from white
range (C).
While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
Input from the engine coolant temperature sensor (temperature) can be checked with monitoring
function.
(Code 04105: Engine coolant temperature)
Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated
(if yes, diagnose that failure first.)
Cause
TWTR (male)

temperature sensor
1
short circuit)
Between (B) (A)
Between (B)
chassis ground
Possible causes
and standard
value in normal
state
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
All range
Min. 1 Mz

TWTR (female) (A)
Wiring harness between TWTR (female) (A)
chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
ResisTWTR (female) (A) and chassis ground
tance
a
Min. 1 Mz

4
24V circuit) in wiring harness Wiring harness between CE01 (female) (15)
Voltage
TWTR (female) (A) and chassis ground
Max. 1 V
CE01 (female)

Between (15)
chassis ground
24
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to engine coolant temperature sensor
PC400, 450-7E0
25
SEN03604-00
40 Troubleshooting
E-12 Hydraulic oil temperature gauge does not indicate normally
Trouble
While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related
information
Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
(Code 04402: Hydraulic oil temperature)
Cause
a
Defective hydraulic oil temperature sensor
1
short circuit)
P22 (male)
Between (1) (2)

Between (2)
chassis ground
Possible causes
and standard
value in normal
state
90 3.5 kz
10 100C
Min. 1 Mz

P22 (female) (2)
P22 (female) (1)
Resistance
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a

4
Voltage
a
Min. 1 Mz
Max. 1 V
P02
Between (12) (13)

Between (12)
chassis ground
Resistance
90 3.5 kz
10 100C
Min. 1 Mz
Circuit diagram related to hydraulic oil temperature sensor
26
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
E-13 Fuel level gauge does not operate normally

Trouble
Related
information
While fuel is added, fuel level gauge does not rise from red range (E).
While fuel level is low, fuel level gauge does not lower from green range (F)
Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
(Code 04200: Fuel level sensor voltage)
Cause
a
Defective fuel level sensor
short circuit)
P21 (male)
Fuel level
Resistance
Between (1)
chassis ground
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z

Wiring
harness between P02 (female) (2)
Resisdefective contact in connector)
P21 (female) (1)
tance
Possible causes
and standard
value in normal
state

3
tance
a
Min. 1 Mz

4
Voltage
a
Max. 1 z
Max. 1 V
P02
Fuel level
Resistance
Between (2)
chassis ground
FULL (Upper limit)
Approx. 12 z
EMPTY (Lower limit)
85 110 z
Circuit diagram related to fuel level sensor
PC400, 450-7E0
27
SEN03604-00
40 Troubleshooting
E-14 Swing lock monitor does not indicate normally

Trouble
Related
information
When swing lock switch is turned ON, swing lock monitor does not light up.
When swing lock switch is turned ON, swing lock monitor lights up.
Input from swing lock switch (ON/OFF) can be checked with monitoring function.
Cause
a
Defective swing lock switch
short circuit)
S04 (female)
Between (1) (2)
Possible causes
and standard
value in normal
state
Swing lock switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

defective contact in connector) J02 S04 (male) (1)
J05 chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
ResisJ02 S04 (male) (1) and chassis ground
tance
a

4
Voltage
J02 S04 (male) (1) and chassis ground
a
28
Min. 1 Mz
Max. 1 V

P02
Swing lock switch
Voltage
Between (17)
chassis ground
OFF
20 30 V
ON
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to swing lock switch
PC400, 450-7E0
29
SEN03604-00
40 Troubleshooting
E-15 When monitor switch is operated, monitor displays nothing

Trouble (1)
Operating the working mode select switch fails to display working mode monitor.
Related
information
Possible causes
and standard
value in normal
state
Cause

Trouble (2)
When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related
information
Possible causes
and standard
value in normal
state
If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
Cause

Trouble (3)
Operating the travel speed select switch fails to display travel speed monitor.
Related
information
Possible causes
and standard
value in normal
state
If travel speed selection fails, proceed with troubleshooting No. H-22.
Cause

Trouble (4)
When wiper switch is operated, wiper monitor is not displayed.
Related
information
Possible causes
and standard
value in normal
state
If wiper fails to operate, proceed with troubleshooting No. E-16.
Cause

Trouble (5)
When select switch is operated, adjust screen is not displayed.

When LCD monitor adjust switch is operated, adjust screen is not displayed.
When maintenance switch is operated, maintenance item screen is not displayed.
Related
information
Possible causes
and standard
value in normal
state
30
Cause

PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
31
SEN03604-00
40 Troubleshooting
E-16 Windowshield wiper does not operate

Trouble
Related
information
Windshield wiper and window washer do not operate
1
(1) Windshield wiper does not operate.
Input from window limit switch (ON/OFF) can be checked with monitoring function.
Cause
a
Defective window rear limit
switch
1
short circuit)
W03 (male)
Between (1) (2)
a
short circuit)
Front window
Resistance
When installed to
front
Min. 1 Mz
When retracted to
rear
Max. 1 z
W04 (male)
Resistance
Between (3) (1)

Between (3), (1)
chassis ground
Possible causes
and standard
value in normal
state

W04 (male) (3)
W04 (male) (1)
a
4
Between (15)
chassis ground
5
a
(Wiper motor system)
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz

P02

(Window limiter switch system)
Resistance

W03 (male) (2) and chassis ground
32
Min. 1 Mz
Front window
Voltage
When installed to
front
20 30 V
When retracted to
rear
Max. 1 V

P01
Wiper switch
Voltage
Between (9)
chassis ground
Between (10)
chassis ground
OFF
Max. 3 V
ON
Max. 3 V
20 30 V
(Constant cycle)
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to windshield wiper motor
PC400, 450-7E0
33
SEN03604-00
Trouble
40 Troubleshooting
Windshield wiper and window washer do not operate
(2) Window washer does not operate.
Related
information
Cause

If fuse is broken, circuit probably has ground fault (See cause 4).
a
Defective washer motor
short circuit)
M06 (male)
Resistance
Between (1) (2)
5 20 z
Min. 1 Mz
Possible causes
and standard
value in normal
state

Wiring harness between F01-4 J03 J06
M06 (female) (1)
Wiring harness between M06 (female) (2)
J04 P01 (female) (3)

J04 P01 (female) (3), D02 (female) (8)
and chassis ground

(Window limiter switch system)
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

P01
Between (3)
chassis ground
34
Max. 1 z
Wiring harness between F01-4 J03 J06

M06 (female) (1), D02 (female) (4), other
4
(Short circuit with GND circuit) harnesses between related circuits and
chassis ground
Resistance
Window washer
switch
Voltage
OFF
20 30 V
ON
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to window washer motor of machine monitor
PC400, 450-7E0
35
SEN03604-00
40 Troubleshooting
E-17 Machine push-up function does not operate normally

Trouble
Related
information
Machine push-up function does not operate normally
(1) Machine push-up function does not operate.
When machine push-up function is set to high pressure, solenoid is de-energized.
Cause
1 Defective fuse No.2

If fuse is broken, circuit probably has ground fault. (See Cause 6)
a
2
Defective machine push-up

switch (Internal disconnection)
S05 (female)
Between (1) (2)
a
solenoid
3
short circuit or ground fault)
Possible causes
and standard
value in normal
state
4 diode D02
Machine push-up
switch
Resistance
Low pressure set
Max. 1 z
High pressure set
Min. 1 Mz
V06 (male)
Resistance
Between (1) (2)
20 60 z
Min. 1 Mz
D02 (male)
Resistance (Continuity)
Between (3) (7)
Min. 1 Mz (without continuity)

Disconnection in wiring harness (male) (1)
defective contact in connector) Wiring harness between S05 (male) (2)
J07 V06 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

chassis ground
Resistance
Max. 1 z

Ground fault in wiring harness (male) (1), other harnesses between
6
(Short circuit with GND circuit) related circuits and chassis ground
J07 V06 (female) (2), D02 (female) (3)
and chassis ground
36
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
Trouble
Related
information
SEN03604-00
Machine push-up function does not operate normally
(2) Machine push-up function does not release.
When machine push-up function is set to low pressure, solenoid is energized.
Cause
Possible causes
and standard
value in normal
state

switch (Internal short circuit)
S05 (female)
Between (1) (2)
a
2
Machine push-up
switch
Resistance
Low-pressure set
Max. 1 z
High-pressure set
Min. 1 Mz


24V circuit) in wiring harness Wiring harness between S05 (female) (2)
J07 V06 (female) (2), D02 (female) (3)
and chassis ground
Voltage
Max. 1 V
Circuit diagram related to machine push-up solenoid
PC400, 450-7E0
37
SEN03604-00
40 Troubleshooting
E-18 Monitoring function fails to display boom RAISE normally

Trouble
Related
information
Boom Raise operation is not displayed normally by machine monitoring function (Special functions)
Monitoring code: 01900 (Pressure Switch 1)
Cause
a
Defective boom RAISE PPC
1 oil pressure switch (Internal
disconnection or short circuit)

P06 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Boom lever
Resistance
Neutral
Min. 1 Mz
Boom RAISE
Max. 1 z

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4
Min. 1 Mz


38
Voltage
Max. 1 V

CP03
Boom lever
Voltage
Between (10)
chassis ground
Neutral
20 30 V
Boom RAISE
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to boom RAISE PPC oil pressure switch
PC400, 450-7E0
39
SEN03604-00
40 Troubleshooting
E-19 Monitoring function fails to display boom LOWER normally

Trouble
Related
information
Boom LOWER operation is not displayed normally by machine monitoring function (Special functions)
Monitoring code: 01900 (Output Switch 1)
Cause
a
Defective boom LOWER
1
short circuit)
Between (1) (2)
Boom lever
Resistance
Neutral
Min. 1 Mz
LOWER
Max. 1 z

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4
Min. 1 Mz


40

P02 (male)
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V

CP03
Boom lever
Voltage
Between (20)
chassis ground
Neutral
20 30 V
LOWER
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to boom LOWER PPC oil pressure switch
PC400, 450-7E0
41
SEN03604-00
40 Troubleshooting
E-20 Monitoring function fails to display arm INnormally

Trouble
Related
information
Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Cause
a
Defective arm IN pressure
sensor
1
short circuit)
Possible causes
and standard
value in normal
state

P04
Voltage
Between (3) (1)
4.5 5.5 V
Between (2) (1)
0.5 4.5 V

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4


a
Min. 1 Mz
Voltage
Max. 1 V

CP01
Voltage
Between (22) (10)
4.5 5.5 V
Between (19) (10)
0.5 4.5 V
Circuit diagram related to arm IN PPC oil pressure witch
42
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
43
SEN03604-00
40 Troubleshooting
E-21 Monitoring function fails to display arm OUT normally

Trouble
Related
information
Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Cause
a
Defective arm OUT PPC oil
1 pressure switch (Internal disconnection or short circuit)

P08 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Arm lever
Resistance
Neutral
Min. 1 Mz
OUT
Max. 1 z

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4
Min. 1 Mz


44
Voltage
Max. 1 V

CP03
Arm lever
Voltage
Between (40)
chassis ground
Neutral
20 30 V
OUT
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to arm OUT PPC oil pressure switch
PC400, 450-7E0
45
SEN03604-00
40 Troubleshooting
E-22 Monitoring function fails to display bucket CURLnormally

Trouble
Related
information
Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Cause
a
Defective bucket CURL pres1 sure sensor (internal disconnection or short circuit)

P01 (male)
Bucket lever
Voltage
Between (3) (1)
Neutral
4.5 5.5 V
Between (2) (1)
CURL
0.5 5.5 V
Possible causes
and standard
value in normal
state

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4


a
Min. 1 Mz
Voltage
Max. 1 V

CP01
Voltage
Between (22) (10)
4.5 5.5 V
Between (13) (10)
0.5 5.5 V
Circuit diagram related to bucket CURL PPC oil pressure switch
46
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03604-00
47
SEN03604-00
40 Troubleshooting
E-23 Monitoring function fails to display bucket DUMP normally

Trouble
Related
information
Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Cause
a
Defective bucket DUMP PPC
1 oil pressure switch (Internal
disconnection or short circuit)

P05 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Bucket lever
Resistance
Neutral
Min. 1 Mz
Dump
Max. 1 z

chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4
Min. 1 Mz


48
Voltage
Max. 1 V

CP03
Bucket lever
Voltage
Between (19)
chassis ground
Neutral
20 30 V
Dump
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to bucket DUMP PPC oil pressure witch
PC400, 450-7E0
49
SEN03604-00
40 Troubleshooting
E-24 Monitoring function fails to display swing normally

Trouble
Related
information
Swing is not displayed normally by machine monitoring function (Special function)

Cause
a
Defective swing left PPC oil

P07 (male)
Between (1) (2)
a
Defective swing right PPC oil
P03 (male)
Resistance
Neutral
Min. 1 Mz
Left
Max. 1 z
Swing lever
Resistance
Neutral
Min. 1 Mz
Right
Max. 1 z

Disconnection in wiring harness P03 (female) (2), P07 (female) (2)
defective contact in connector) Wiring harness between P03 (female) (1)
chassis ground
chassis ground
a
4
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz


P03 (female) (2), P07 (female) (2) and
chassis ground
Resistance

P03 (female) (2), P07 (female) (2) and
chassis ground
50
Swing lever

Between (1) (2)
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V

CP03
Bucket lever
Voltage
Between (29)
chassis ground
Neutral
20 30 V
Left or Right
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to right and left swing PPC oil pressure witches
PC400, 450-7E0
51
SEN03604-00
40 Troubleshooting
E-25 Monitoring function fails to display travel normally

Trouble
Related
information
Travel is not displayed normally by machine monitoring function (Special functions)

Cause
a
Defective travel PPC pressure switch
1
short circuit)
Between (1) (2)
Travel lever
Resistance
Neutral
Min. 1 Mz
Front or rear
Max. 1 z

defective contact in connector) J01 P09 (female) (2)
J05 chassis ground
a
3
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz


J01 P09 (female) (2), M14 (female) (2)
and chassis ground
Resistance

J01 P09 (female) (2), M14 (female) (2)
and chassis ground
52

P09 (male)
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V

CP03
Travel lever
Voltage
Between (39)
chassis ground
Neutral
20 30 V
Front or rear
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-7E0
53
SEN03604-00
40 Troubleshooting
E-26 Monitoring function fails to display travel differential pressure

normally
1
Trouble
Travel differential pressure is not displayed normally by machine monitoring function (Special functions)
Related
information
Travel differential pressure is turned on as a pressure difference occurred between the right and left
travel PPC circuits (during steering).
Cause
a
Defective travel steering
1
short circuit)
P10 (male)
Between (1) (2)
Possible causes
and standard
value in normal
state
Travel lever
Resistance
Neutral
Min. 1 Mz
Left or Right only
Max. 1 z

P10 (female) (2)
J05 chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
tance
a
4
Min. 1 Mz


54

Voltage
Max. 1 V

CP02
Travel lever
Voltage
Between (16)
chassis ground
Neutral
20 30 V
Left or Right only
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to travel steering PPC oil pressure switch
PC400, 450-7E0
55
SEN03604-00
40 Troubleshooting
E-27 Monitoring function fails to display service normally

Trouble
Related
information
Service is not displayed normally by machine monitoring function (Special functions)

Cause
a
Defective (front) PPC oil

S10 (male)
Between (1) (2)
a
Defective (rear) PPC oil
S11(male)
Resistance
Neutral
Min. 1 Mz
Front
Max. 1 z
Service pedal
Resistance
Neutral
Min. 1 Mz
Rear
Max. 1 z

Disconnection in wiring harness S10 (female) (2), S11 (female) (2)
defective contact in connector) Wiring harness between S10 (female) (1)
chassis ground
chassis ground
a
4
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Min. 1 Mz


S10 (female) (2), S11 (female) (2) and chassis ground
Resistance

S10 (female) (2), S11 (female) (2) and chassis ground
56
Service pedal

Between (1) (2)
Possible causes
and standard
value in normal
state
Voltage
Max. 1 V

CP02
Service pedal
Voltage
Between (35)
chassis ground
Neutral
20 30 V
Front or rear
Max. 1 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to service PPC oil pressure switch
PC400, 450-7E0
57
SEN03604-00
40 Troubleshooting
E-28 The KOMTRAX system does not operate normally

Trouble
Related
information
The KOMTRAX system does not operate normally

If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
system, carry out the following troubleshooting.
A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.
Cause

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
1 Defective power supply
G01
Signal
Between (39), (40) Constant power sup(37) and (38)

ply
Voltage
20 30 V
a Turn the starting switch ON, then start engine and carry out troubleshooting.
LED (1)
Normal state
LED-C1
ON

a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R
troubleshooting.
signal
G01
Signal
Voltage
Possible causes
and standard
value in normal
state
Defective starting switch C

signal
Between (36) and

(37), (38)
Starting switch ACC
20 30 V
Between (28) (37),

(38)
Alternator R
20 30 V
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
G01
Signal
Voltage
Between (27) and

(37), (38)
Starting switch C
20 30 V
a Turn the starting switch ON, and carry out troubleshooting.
Defective CAN connection

4
state
LED (4)
Normal state
LED-C4
ON
a Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
G01 (female)
Signal
Resistance
Between (7) and (8)
CAN
40 80 z

5 Number of unsent mails
LED (7)
Normal state
7 segments
09

Defective GPS positioning
6
status
58
LED (8)
Normal state
Dot
ON
One or more minute may be taken until GPS positioning is completed after the starting switch was turned ON even in an outdoor
service area.
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Indicator lamps of KOMTRAX terminal
G01 connector
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
7-segment and dot displays for CPU

7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)
PC400, 450-7E0
59
SEN03604-00
40 Troubleshooting
E-29 Air conditioner does not operate

Trouble
Related
information
Air conditioner does not start.

For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance
standard, Air conditioner system.
Cause

If fuse is burnt, circuit probably has ground fault.
Defective A/C Hi/Lo pressure a

switch
2
defective contact)
P17 (Male)
Resistance
Between (1) (2)
Max. 1 z
Wiring harness between F01-11 outlet M26

(male) (5)
Possible causes
and standard
value in normal
state

Wiring harness between M26 (male) (12)
chassis ground

J04 A07 chassis ground
a
4

P17 (female) (1)
5 Defective air conditioner unit
60
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harness Wiring harness between F01-11 outlet M26
(Short circuit with GND circuit) (male) (5) and chassis ground
Resistance
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(The table indicates internal defect of an air conditioner)
M26
Voltage
Between (5) (8)
20 30 V
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to air conditioner
PC400, 450-7E0
61
SEN03604-00
40 Troubleshooting
E-30 Travel alarm does not sound or does not stop sounding
Trouble
Related
information
Alarm does not sound during travel.

Alarm sounds in stopped state.
Cause

2 Defective travel signal
Monitoring code
Item
Normal display
01900
Travel
Operation of lever:
ON
When the monitoring display is not correct, proceed to diagnosis for

Travel is not normally indicated' in the monitoring function
Possible causes
and standard
value in normal
state
Defective travel alarm

short circuit)

carry out troubleshooting (insert T-adapter).
M14
Between (1) (2)
Travel lever
Voltage
Neutral
Max. 1 V
Operated
20 30 V
If above voltage is normal and travel alarm does not sound, travel
alarm is defective.

A07 M14 (female) (1)
J01 (19)
Resistance
Max. 1 z
Resistance
Max. 1 z

5
(Short circuit with GND circuit) Wiring harness between F01-15 outlet J03
ResisA07 A14 (female) (1) and chassis ground
tance
62
Min. 1 Mz

causes 1 5 above are not detected, travel alarm may be defective.)
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-7E0
63
SEN03604-00
40 Troubleshooting
E-31 Horn does not sound

Trouble
Horn does not sound
Related
information
Cause
If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay
If the horn sounds after replacing the relay, the relay was defective

Between M07 (2) chassis ground (with

horn switch turned ON)
3 Defective high tone horn
Voltage
20 30 V
Between M07 (female) (1) chassis ground
Resistance
Max. 1 z
If above is normal, the horn is defective

Between M08 (2) chassis ground (with

horn switch turned ON)
4 Defective low tone horn
Possible causes
and standard
value in normal
state
20 30 V
Between M08 (female) (1) chassis ground
Resistance
Max. 1 z
If above is normal, the horn is defective
Wiring harness between F01 (5) S10

(female) R08 (female) (3)

R08 (female) A07 M07 (female) (2)
A07 M08 (female) (2)
J04 (20) A07 chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Wiring harness between F01 (5) S10

(female) R08 (female) (3) and chassis
Ground fault in wiring harness ground
6
(Short circuit with GND circuit) Wiring harness between S10 (female) (2)
R08 (female) A07 M07 (female) (2) and
chassis ground
A07 M08 (female) (2) and chassis ground
64
Voltage
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
PC400, 450-7E0
40 Troubleshooting
SEN03604-00
Circuit diagram related to horn
PC400, 450-7E0
65
SEN03604-00

2008 KOMATSU
All Rights Reserved
66
SEN03605-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting
Troubleshooting of hydraulic and mechanical

system (H-mode)
System chart for hydraulic and mechanical system ........................................................................................ 4
Information contained in troubleshooting table ............................................................................................... 6
H-1 All work equipment lack power, or travel and swing speeds are slow...................................................... 8
H-2 Engine speed sharply drops or engine stalls.......................................................................................... 10
H-3 No work equipment, swing or travel move ..............................................................................................11
H-4 Abnormal noise is heard from around hydraulic pump............................................................................11
H-5 Auto-decelerator does not work ............................................................................................................. 12
H-6 Fine control mode does not function or responds slow.......................................................................... 12
H-7 Boom moves slowly or lacks power ....................................................................................................... 13
H-8 Arm moves slowly or lacks power .......................................................................................................... 14
H-9 Bucket moves slowly or lacks power...................................................................................................... 15
H-10 Work equipment does not move in its single operation........................................................................ 15
H-11 Work equipment has a bit too fast hydraulic drift.................................................................................. 16
H-12 Work equipment has big time lag ......................................................................................................... 18
PC400, 450-7E0
SEN03605-00
40 Troubleshooting
H-13 Other work equipment moves when relieving single circuit.................................................................. 18

H-14 Power max. switch does not operate ................................................................................................... 18
H-15 Machine push-up function does not operate. ....................................................................................... 19
H-16 In compound operation of work equipment, speed of part loaded more is low .................................... 20
H-17 When machine swings and raises boom simultaneously, boom rising speed is low ............................ 20
H-18 When machine swings and travels simultaneously, travel speed lowers largely.................................. 20
H-19 Machine deviates during travel............................................................................................................. 21
H-20 Travel speed is low............................................................................................................................... 22
H-21 Machine is not steered well or steering power is low ........................................................................... 23
H-22 Travel speed does not change or travel speed is low or high .............................................................. 24
H-23 Travel system does not move (only one side) ...................................................................................... 25
H-24 Upper structure does not swing............................................................................................................ 26
H-25 Swing acceleration or swing speed is low ............................................................................................ 28
H-26 Upper structure overruns remarkably when it stops swinging .............................................................. 30
H-27 Large shock is made when upper structure stops swinging ................................................................. 31
H-28 Large sound is made when upper structure stops swinging. ............................................................... 31
H-29 Hydraulic drift of swing is large............................................................................................................. 32
H-30 Attachment circuit is not changed ........................................................................................................ 33
H-31 Oil flow in attachment circuit cannot be controlled ............................................................................... 33
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03605-00
SEN03605-00
System chart for hydraulic and mechanical system
40 Troubleshooting
PC400, 450-7E0
40 Troubleshooting
a
SEN03605-00
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical system.
PC400, 450-7E0
SEN03605-00
40 Troubleshooting
Information contained in troubleshooting table

a
Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure
Phenomenon occurring on machine
phenomenon
Relative
information
Information on the failure occurred as well as the troubleshooting
Cause
Standard value in normalcy and references for troubleshooting
Presumed
cause and
standard value
in normalcy
Cause for presumed failure

[Contents]
(The attached No. is for fil The standard values in normalcy by which to judge Good
3 ing and reference purpose
or No Good about presumed causes.
only. It does not stand for
References for making judgement of good or No Good
any priority.)
4
5
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03605-00
SEN03605-00
40 Troubleshooting
H-1 All work equipment lack power, or travel and swing speeds are slow1
Trouble
Related
information
Speed or power of all work equipment, travel, and swing is low

Set the working mode in P-mode before start.
Cause
a
1 Malfunction of unload valve
Prepare with engine stopped, then run engine at high

idle and carry out troubleshooting.
Control lever
Unload pressure
4.12 1.0 MPa

{42 10 kg/cm2}

Control lever
Main relief pressure
Arm IN
33.34 36.77 MPa

{340 375 kg/cm2}
Defective adjustment or mal2

function of main relief valve
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
a
Possible causes
and standard
value in normal
state
Malfunction of self pressure

reducing valve

Control lever
Control circuit basic pressure
2.84 3.43 MPa

{29 35 kg/cm2}

Measured oil
pressure
Defective adjustment or malfunction of PC valve
Pump discharge
pressure
PC valve output
pressure
Measurement condition
Arm IN relief
Oil pressure ratio

1
Approx. 0.6
(Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve

may have malfunction or internal defect. Check PC valve directly.
5 Malfunction of LS-EPC valve

Travel speed
Travel lever
LS-EPC output
pressure
Lo
Neutral
Approx. 1.37 MPa

{Approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
Cause

Oil pressure ratio
Measured oil
pressure
Possible causes
and standard
value in normal
state
Defective adjustment or malfunction of LS valve
Pump discharge
pressure
LS valve output
pressure
Almost same pressure
Travel with no load

(Lever operated
halfway)
1
Approx. 0.6
(Approx. 3/5)
If oil pressure does not become normal after adjustment, LS valve

may have malfunction or internal defect. Check LS valve directly.
PC400, 450-7E0
7 Malfunction of servo piston
Servo piston may have malfunction. Check it directly.
8 Defective piston pump
If any cause above is detected, cause may be lowering of performance, malfunction, or internal defect of piston pump.
SEN03605-00
40 Troubleshooting
H-2 Engine speed sharply drops or engine stalls

Trouble
Related
information
Engine speed lowers extremely or engine stalls.

Cause

function of main relief valve

Control lever
Main relief pressure
Arm IN
33.34 36.77 MPa

{340 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.

Measured oil
pressure
Defective adjustment or malfunction of PC valve
Pump discharge
pressure
PC valve output
pressure
Possible causes
and standard
value in normal
state
Measurement
condition
Arm IN relief
Oil pressure ratio

1
Approx. 0.6
(Approx. 3/5)
If oil pressure does not become normal after adjustment, PC valve

may have malfunction or internal defect. Check PC valve directly.

Oil pressure ratio
Measured oil
pressure
Pump discharge
pressure
LS valve output
pressure
Almost same
pressure
Travel with no load

(Lever operated
halfway)
1
Approx. 0.6
(Approx. 3/5)

4
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
servo devices
them directly.
10
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-3 No work equipment, swing or travel move

Trouble
Related
information
All work equipment, swing, and travel mechanism do not move.

Cause
a
1
Possible causes
and standard
value in normal
state
Malfunction of PPC lock

solenoid valve
a
2

reducing valve

Work equipment lock lever
Solenoid output pressure
Lock
0 MPa {0 kg/cm2}
Free
2.84 3.43 MPa

{29 35 kg/cm2}

Control lever
2.84 3.43 MPa

{29 35 kg/cm2}
3 Defective piston pump
Piston pump may have malfunction or internal defect. Check it by

following method.
Crank the engine with oil pressure measurement plug removed.
If oil flows out, the piston pump is normal.
4 Defective damper
Pump shaft may not revolve because of defect in damper. Check

damper directly.
H-4 Abnormal noise is heard from around hydraulic pump

Failure
phenomenon
An abnormal noise is heard from around hydraulic pump.
Relative
information
Cause
Presumed
cause and
standard value
in normalcy
1 Hydraulic oil level lowered
Make a visual check.
2 Quality of hydraulic oil bad
Air may have get mixed with the oil. Make a visual check.
3 Hydraulic tank cap clogged
It is presumed that the cap of hydraulic tank is clogged, thereby

causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer

clogged
It is presumed that the strainer in the hydraulic tank is clogged,

thereby causing negative pressure in the suction circuit. Make a
visual check.
5 Piston pump defective
PC400, 450-7E0
Standard value in normalcy and references for troubleshooting
The piston pump is suspected of an internal failure. Check the pump

itself.
11
SEN03605-00
40 Troubleshooting
H-5 Auto-decelerator does not work

Trouble
Related
information
Auto-decelerator does not operate.

Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated.
(Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
circuit.)
Cause
a
Possible causes
and standard
value in normal
state
Malfunction of travel PPC

valve (shuttle valve)

Travel lever
PPC valve output pressure
Neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.75 MPa

{Min. 28 kg/cm2}
H-6 Fine control mode does not function or responds slow

Trouble
Fine control performance or response is low.
Related
information
Cause

Travel speed
Travel lever
LS-EPC output
pressure
Lo
Neutral
Approx. 1.37 MPa

{Approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}
2 Clogging of LS circuit orifice Orifice of LS circuit may be clogged. Check it directly.
Possible causes
and standard
value in normal
state

Oil pressure ratio
Measured oil
pressure
Pump discharge
pressure
LS valve output
pressure
Almost same pressure
Travel with no load

(Lever operated
halfway)
1
Approx. 0.6
(Approx. 3/5)

12
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-7 Boom moves slowly or lacks power

Trouble
Related
information
Speed or power of boom is low

Cause
a
Malfunction of right PPC
1
valve (boom circuit)
R.H. work equipment control

lever
Neutral
0 MPa {0 kg/cm2}
In boom Raise operation

In boom Lower operation
Min. 2.75 MPa

{Min. 28 kg/cm2}
a
2
Malfunction of merge-divider
solenoid valve

Travel lever
At neutral
0 MPa {0 kg/cm2}
Operated (Note)
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of merge-divider Merge-divider valve (main/LS) of control valve may have malfuncvalve (main/LS)
tion. Check it directly.
Malfunction of boom control

valve (spool)

5 valve (pressure compensation valve)
Possible causes
and standard
value in normal
state

Spool of boom control valve (Lo/Hi) may have malfunction. Check it

directly.
Pressure compensation valve of boom control valve (Lo/Hi) may
have malfunction. Check it directly.

valve (regeneration valve)
Regeneration valve of boom control valve (Lo) may have malfunction or defective seal. Check it directly.

valve (lock valve)
Lock valve of boom control valve (Lo) may have malfunction. Check
it directly.

valve (check valve)
Check valve of boom control valve (Hi) may have malfunction.

Check it directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
of safety valve for lock valve Check it directly.
Malfunction or defective seal

Suction valve (bottom side) of boom control valve (Lo) may have
10 of boom control valve
malfunction or defective seal. Check it directly.
(suction valve)
Safety-suction valve (head side) of boom control valve (Lo) may
11 of boom control valve
have malfunction or defective seal. Check it directly.
(safety-suction valve)
Malfunction of LS shuttle
LS shuttle valve of left travel control valve, bucket control valve, or
12 valve
service control valve may have malfunction. Check it directly.
(left travel, bucket, or service)
a
13 Defective boom cylinder

Boom cylinder
Leakage from cylinder
Boom raise relief
20 cc/min
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
PC400, 450-7E0
13
SEN03605-00
40 Troubleshooting
H-8 Arm moves slowly or lacks power

Trouble
Related
information
Speed or power of arm is low

Cause
a
Malfunction of left PPC valve
1
(arm circuit)
a
2
Possible causes
and standard
value in normal
state
solenoid valve

L.H. work equipment control
lever
At neutral
0 MPa {0 kg/cm2}
During arm IN operation

During arm OUT operation
Min. 2.75 MPa

{Min. 28 kg/cm2}

Travel lever
At neutral
0 MPa {0 kg/cm2}
Operated (Note)
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of pump merge- Pump merge-divider valve (main/LS) of control valve may have maldivider valve (main/LS)
function. Check it directly.
Malfunction of arm control

valve (spool)

6

valve (regeneration valve)
Spool of arm control valve (Lo/Hi) may have malfunction. Check it

directly.
Pressure compensation valve of arm control valve (Lo/Hi) may have
malfunction. Check it directly.
Regeneration valve of arm control valve (Lo) may have malfunction
or defective seal. Check it directly.

Safety-suction valve of arm control valve (Lo/Hi) may have malfunc7 of arm control valve (safetytion or defective seal. Check it directly.
suction valve)
8

valve (quick return valve)
Quick return valve of arm control valve (Hi) may have malfunction.
Check it directly.
LS shuttle valve of right travel control valve, boom control valve, left
9 valve (right travel, boom, left travel control valve, bucket control valve, or service control valve
travel, bucket, or service)
may have malfunction. Check it directly.
a
10 Defective arm cylinder

Arm cylinder
Arm IN relief
20 cc/min
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
14
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-9 Bucket moves slowly or lacks power

Trouble
Related
information
Speed or power of bucket is low

Cause
a
Malfunction of right PPC
1
valve (bucket circuit)
Possible causes
and standard
value in normal
state

R.H. work equipment control

lever
At neutral
0 MPa {0 kg/cm2}
During bucket CURL operation

During bucket DUMP operation
Min. 2.7 MPa

{Min. 28 kg/cm2}
Malfunction of bucket control Spool of bucket control valve may have malfunction. Check it
valve (spool)
directly.
Malfunction of bucket control

Pressure compensation valve of bucket control valve may have mal3 valve (pressure compensafunction. Check it directly.
tion valve)
Safety-suction valve of bucket control valve may have malfunction
4 of bucket control valve
or defective seal. Check it directly.
5
valve (service)
LS shuttle valve of service control valve may have malfunction.

Check it directly.
a
6 Defective bucket cylinder

Bucket cylinder
CURL relief
20 cc/min
H-10 Work equipment does not move in its single operation

Trouble
Related
information
Work equipment does not move singly
(1)
(2)
(3)
(4)
Boom does not move singly.

Arm does not move singly.
Bucket does not move singly.
Bottom dump does not move singly. (For loading
shovel)
Cause
a
Possible causes
and standard
value in normal
state
1 Malfunction of PPC valve
PC400, 450-7E0
Malfunction of control valve

(spool)

Work equipment control lever
At neutral
0 MPa {0 kg/cm2}
Operated
Min. 2.75 MPa

{Min. 28 kg/cm2}
Spool of control valve may have malfunction. Check it directly.
15
SEN03605-00
40 Troubleshooting
H-11 Work equipment has a bit too fast hydraulic drift

Trouble
Related
information
Hydraulic drift of work equipment is large
Trouble
Related
information
1 Defective boom cylinder

Boom cylinder
Boom RAISE relief
20 cc/min
Defect in seal of boom control valve (lock valve)
Seal of lock valve of boom control valve (Lo) may be defective.

Check it directly.
Defective seal of safety valve

Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
(2) Hydraulic drift of arm is large.
Cause
a
1 Defective arm cylinder
Possible causes
and standard
value in normal
state
(1) Hydraulic drift of boom is large.
Cause
Possible causes
and standard
value in normal
state

Arm cylinder
Arm IN relief
20 cc/min
Seal of safety-suction valve of arm control valve (Lo/Hi) may be

defective. Check it directly.
Defective seal of arm control
2
(When troubleshooting this safety-suction valve, it is allowed to
valve (safety-suction valve)
replace it with another one to see the change in phenomena and
judge its acceptability.)
3
Defective seal of arm control Seal of spool of arm control valve (Lo/Hi) may be defective. Check it
valve (spool)
directly.
Defective seal of arm control

Seal of pressure compensation valve (bottom side) of arm control
4 valve (pressure compensavalve (Lo/Hi) may be defective. Check it directly.
tion valve)
16
PC400, 450-7E0
40 Troubleshooting
Trouble
Related
information
SEN03605-00
(3) Hydraulic drift of bucket is large.
Cause
a
1 Defective bucket cylinder
Possible causes
and standard
value in normal
state

Bucket cylinder
Bucket curl relief
20 cc/min
Seal of safety-suction valve of bucket control valve may defective.

Defective seal of bucket con- Check it directly.
2 trol valve (safety-suction
valve)
3
Defective seal of bucket con- Seal of bucket control valve spool may be defective. Check it
trol valve (spool)
directly.
Defective seal of valve conSeal of pressure compensation valve (bottom side) of bucket control
4 trol valve (pressure compenvalve may be defective. Check it directly.
sation valve)
PC400, 450-7E0
17
SEN03605-00
40 Troubleshooting
H-12 Work equipment has big time lag

Trouble
Related
information
Time lag of work equipment is large.

Cause
Possible causes
and standard
value in normal
state

2 (regeneration valve)
[boom and arm only]

Travel speed
Travel lever
LS-EPC output
pressure
Lo
Neutral
Approx. 1.37 MPa

{Approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}
Regeneration valve of control valve may have malfunction. Check it

directly.
Safety-suction valve (Boom: Head side, Arm/Bucket: Bottom side)
of control valve may have malfunction. Check it directly.

Malfunction of control valve Pressure compensation valve of control valve may have malfunc(pressure compensation valve) tion. Check it directly.
H-13 Other work equipment moves when relieving single circuit

Trouble
Related
information
Possible causes
and standard
value in normal
state
When part of work equipment is relieved singly, other parts of work equipment move
Cause
Defective seal of control

Seal of pressure compensation valve of control valve may be defective. Check it directly.
H-14 Power max. switch does not operate

Trouble
The power maximizing function does not work.
Related
information
Cause
Malfunction of 2-stage relief

solenoid valve
a
Possible causes
and standard
value in normal
state

Swing lock switch
OFF
0 MPa {0 kg/cm2}
ON
2.84 3.43 MPa

{29 35 kg/cm2}
2 Malfunction of main relief valve Main relief valve of control valve may have malfunction. Check it directly.
18
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-15 Machine push-up function does not operate.

Trouble
Machine push-up function does not operate.
Related
information
Cause
a
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Malfunction of machine
push-up solenoid valve

valve (safety-suction valve)

OFF
Min. 2.75 MPa

{Min. 28 kg/cm2}
ON
0 MPa {0 kg/cm2}
Malfunctioning of safety-suction valve (high-voltage set side of head

side) of boom control valve (Lo) is suspected. Check it directly.
19
SEN03605-00
40 Troubleshooting
H-16 In compound operation of work equipment, speed of part loaded

more is low
1
Trouble
Related
information
In compound operation of work equipment, speed of part loaded more is low.
Cause

Malfunctioning of pressure compensation valve on smaller load side
is suspected. Check it directly.
Possible causes
and standard
value in normal
state

on smaller load side
Combinations in compound operation
Larger load side
Smaller load side
Boom RAISE +
Arm IN
Boom
Arm
Boom RAISE +
Arm OUT
Arm
Boom
Boom RAISE +
Bucket CURL
Boom
Bucket
Arm OUT +
Bucket CURL
Arm
Bucket
Boom LOWER +
Arm OUT
Arm
Boom
H-17 When machine swings and raises boom simultaneously, boom

rising speed is low
Trouble
Related
information
Possible causes
and standard
value in normal
state
When machine swings and raises boom simultaneously, boom rising speed is low.
If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
Cause
1
Malfunction or defective seal LS select valve of control valve may have malfunction or defective
of LS selector valve
seal. Check them directly.
H-18 When machine swings and travels simultaneously, travel speed

lowers largely
1
Trouble
Related
information
Possible causes
and standard
value in normal
state
20
When machine swings and travels simultaneously, travel speed lowers largely.
If speed of single travel operation is also slow, carry out troubleshooting of H-20 first.
Cause
1
valve (left travel and swing)

LS shuttle valve of left travel control valve or swing control valve
may have malfunction. Check it directly.
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-19 Machine deviates during travel

Trouble
Related
information
Machine deviates during travel.

Cause
Travel lever
Travel forward or reverse
Min. 2.75 MPa

{Min. 28 kg/cm2}
Difference between right and left

outputs
Within 0.4 MPa

{Within. 4 kg/cm2}

1
valve
a
2


reducing valve

Control lever
2.84 3.43 MPa

{29 35 kg/cm2}

Oil pressure ratio
Possible causes
and standard
value in normal
state
Measured oil
pressure

function of LS valve
Pump discharge
pressure
LS valve output
pressure
a
4
Malfunction of travel junction

solenoid valve
Almost same
pressure
Travel with no load

(Lever operated
halfway)
1
Approx. 0.6
(Approx. 3/5)

Travel lever
Neutral
0 MPa {0 kg/cm2}
When either side operated
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
valve
Check it directly.
Malfunction of travel control

valve (spool)
Spool of travel control valve may have malfunction. Check it directly.
a
7 Defective travel motor
8 Defective final drive
PC400, 450-7E0

Travel lever
Leakage from travel motor
Travel relief
Max. 40 l/min
Final drive may have internal defect. Check it directly.

(It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.)
21
SEN03605-00
40 Troubleshooting
H-20 Travel speed is low

Trouble
Related
information
Travel speed is low.

Cause
Travel lever
Travel forward or reverse
Min. 2.75 MPa

{Min. 28 kg/cm2}
Difference between right and left/

forward and reverse outputs
Within 0.4 MPa

{Within. 4 kg/cm2}

1
valve
a
2

reducing valve
Possible causes
and standard
value in normal
state

Control lever
2.84 3.43 MPa

{29 35 kg/cm2}

Travel speed
Travel lever
LS-EPC output
pressure
Lo
Neutral
Approx. 1.37 MPa

{Approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}

valve (spool)

Pressure compensation valve of travel control valve may have malfunction. Check it directly.

valve (suction valve)
Suction valve of travel control valve may have malfunction. Check it

directly.
valve (bucket)
LS shuttle valve of bucket control valve may have malfunction.

Check it directly.
a
8 Defective travel motor
22


Travel lever
Travel relief
Max. 40 l/min

PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-21 Machine is not steered well or steering power is low

Trouble
Related
information
Machine is not steered well or steering power is low

Cause
a
1
valve (steering spool)
a
2
Malfunction of travel junction

solenoid valve
Possible causes
and standard
value in normal
state
Travel lever

(Steering)
Both sides in neutral
0 MPa {0 kg/cm2}
When either side operated
Min. 2.75 MPa

{Min. 28 kg/cm2}

Travel lever
At neutral
0 MPa {0 kg/cm2}
Either side operated
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
valve
Check it directly.
a
4

solenoid valve

Travel lever
At neutral
0 MPa {0 kg/cm2}
Operated
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of merge-divider Merge-divider valve of control valve may have malfunction. Check it
valve
directly.

valve (spool)

Pressure compensation valve of travel control valve may have malfunction. Check it directly.

valve (suction valve)
Suction valve of travel control valve may have malfunction. Check it

directly.
valve (bucket)
LS shuttle valve of bucket control valve may have malfunction.

Check it directly.
10
Defect in seal of check valve Seal of check valve of LS pressure sensing part may be defective.
of LS pressure sensing part Check it directly.
11
Malfunction of travel motor

(safety valve)
Seal of safety valve of travel motor may have malfunction. Check it

directly.
(Motors of same type on forward and reverse sides or on right and
left sides may be checked by replacing them with each other and
seeing change of condition.)

(check valve)
Check valve of travel motor may have defective seal. Check it

directly.
(Motors of same type on forward and reverse sides or on right and
left sides may be checked by replacing them with each other and
seeing change of condition.)
12
PC400, 450-7E0
23
SEN03605-00
40 Troubleshooting
H-22 Travel speed does not change or travel speed is low or high
Trouble
Related
information
Travel speed does not change or travel speed is or low or high

Cause

Travel speed
Travel lever
Lo
Fine control
(such as releasing
decelerator)
Mi
Hi
Possible causes
and standard
value in normal
state
a
Malfunction of travel speed
2
solenoid valve
24

(speed shifting section)
Monitoring
[01500]
690 mA
740 mA
0 mA

Travel speed
Travel lever
LS-EPC output pressure
Lo
Neutral
Approx. 1.37 MPa

{Approx. 14 kg/cm2}
Hi
Operated
0 MPa {0 kg/cm2}

Travel speed
Travel lever
Solenoid valve output pressure
Lo
Neutral
0 MPa {0 kg/cm2}
Hi
Operated
2.84 3.43 MPa

{29 35 kg/cm2}
Speed shifting section of travel motor may have malfunction. Check

it directly.
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-23 Travel system does not move (only one side)

Trouble
Travel system does not move (only one side).
Related
information
Possible causes
and standard
value in normal
state
Cause
Defective seal of travel con1

trol valve (suction valve)
Suction valve of travel control valve may have defective seal. Check
it directly.
Defective seal of travel motor Safety valve of travel motor may have defective seal. Check it
(safety valve)
directly.
Defective seal of travel motor Check valve of travel motor may have defective seal. Check it
(check valve)
directly.
a
4
Lowering of travel motor output
PC400, 450-7E0

Travel lever
Travel relief
Max. 40 l/min

25
SEN03605-00
40 Troubleshooting
H-24 Upper structure does not swing

Trouble
Related
information
Upper structure does not swing.
(1) Upper structure does not swing in either direction.
Cause
a
Malfunction of swing holding
1
brake solenoid valve
Malfunction of swing motor

(holding brake)
Defective adjustment or mal3 function of swing motor

(safety valve)

R.H. work equipment
control lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
2.84 3.43 MPa

{29 35 kg/cm2}
Holding brake section of swing motor may have malfunction. Check

it directly.
a
Possible causes
and standard
value in normal
state

Swing lock switch
L.H. work equipment

Swing relief pressure
control lever
ON
Swing relief
27.95 32.85 MPa

{285 335 kg/cm2}
If oil pressure does not become normal after adjustment, safety

valve may have malfunction or internal defect. Check safety valve
directly.
a
4 Defective swing motor
5 Defective swing machinery
26

L.H. work equipment
control lever
Leakage from swing motor
Swing relief
Max. 11 l/min
Swing machinery may have internal defect. Check it directly.

PC400, 450-7E0
40 Troubleshooting
Trouble
Related
information
SEN03605-00
Upper structure does not swing.
(2) Upper structure swings only in one direction.
Cause
a
Malfunction of swing PPC
1
valve
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Malfunction of swing control

valve (spool)

lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
Min. 2.75 MPa

{Min. 28 kg/cm2}
Spool of swing control valve may have malfunction. Check it directly.
Defective seal of swing

3
motor (suction valve)
Seal of suction valve of swing motor may be defective. Check it

directly.
(Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.)

4
motor (check valve)
Seal of check valve of swing motor may be defective. Check it

directly.
(Check valves on right side and left side may be checked by replacing them with each other and seeing change of condition.)
27
SEN03605-00
40 Troubleshooting
H-25 Swing acceleration or swing speed is low

Trouble
Related
information
Swing acceleration or swing speed is low
(1) Swing acceleration or swing speed is low in both

directions.
Cause
valve (all control valves)
LS shuttle valves of all control valves may have malfunction. Check

them directly.

(holding brake)
Holding brake section of swing motor may have malfunction. Check

it directly.
Possible causes
and standard
value in normal
state

(safety valve)

Swing lock switch

ON
L.H. work equipment

control lever
Swing relief
27.95 32.85 MPa

{285 335 kg/cm2}

directly.
a

lever
Swing relief
28
Max. 11 l/min

PC400, 450-7E0
40 Troubleshooting
Trouble
Related
information
SEN03605-00
Swing acceleration or swing speed is low
(2) Swing acceleration or swing speed is low in only one

direction.
Cause
Possible causes
and standard
value in normal
state
PC400, 450-7E0

valve

lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
Min. 2.75 MPa

{Min. 28 kg/cm2}

valve (spool)
Spool of swing control valve may have malfunction. Check it directly.

Pressure compensation valve of swing control valve may have malfunction. Check it directly.

4

directly.

5
motor (check valve)

directly.
29
SEN03605-00
40 Troubleshooting
H-26 Upper structure overruns remarkably when it stops swinging

Trouble
Related
information
Upper structure overruns remarkably when (1) Upper structure overruns remarkably when it stops
it stops swinging.
swinging in both directions.
Cause
Possible causes
and standard
value in normal
state

(safety valve)

Swing lock switch
L.H. work equipment

control lever
ON

L.H. work equipment
control lever
Swing relief
Related
information
Max. 11 l/min
Upper structure overruns remarkably when (2) Swing acceleration or swing speed is low in only one
it stops swinging.
direction.
Cause
a
1
valve
Possible causes
and standard
value in normal
state
27.95 32.85 MPa

{285 335 kg/cm2}
Swing relief

directly.
Trouble

lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
Min. 2.75 MPa

{Min. 28 kg/cm2}
Swing PPC slow return valve may be clogged. Check it directly.

Clogging of swing PPC slow
(Slow return valves on right side and left side may be checked by
return valve

valve (spool)
Spool may have malfunction. Check it directly.

directly.
4
motor (suction valve section) (Suction valves on right side and left side may be checked by
5
motor (check valve section)
30

directly.
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-27 Large shock is made when upper structure stops swinging

Trouble
Related
information
Large shock is made when upper structure stops swinging.

Cause
a
1
valve
Possible causes
and standard
value in normal
state

2
slow return valve
3

(shockless valve)

L.H. work equipment
control lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
Min. 2.75 MPa

{Min. 28 kg/cm2}
Swing PPC slow return valve may have malfunction. Check it

directly.
(Slow return valves on right side and left side may be checked by
Shockless valve of swing motor may have malfunction. Check it
directly.
H-28 Large sound is made when upper structure stops swinging.

Trouble
Related
information
Large sound is made when upper structure stops swinging.

Possible causes
and standard
value in normal
state
PC400, 450-7E0
Cause
Malfunction of back pressure valve
Back pressure valve of control valve may have malfunction. Check it

directly.

(safety valve)
Safety valve of swing motor may have malfunction. Check it directly.

3
(suction valve)

directly.

31
SEN03605-00
40 Troubleshooting
H-29 Hydraulic drift of swing is large

Trouble
Related
information
Hydraulic drift of swing is large.
(1) When swing holding brake is in operation
When swing lock switch is turned ON or when swing holding brake release switch is in normal position, swing holding brake is activated, fixing upper structure with disc brake.
Cause
a
Possible causes
and standard
value in normal
state
Trouble
Related
information
Malfunction of swing holding

brake solenoid valve

(holding brake)
Hydraulic drift of swing is large.

R.H. work equipment
control lever
At neutral
0 MPa {0 kg/cm2}
In swing operation
2.84 3.43 MPa

{29 35 kg/cm2}
Holding brake section of swing motor may have malfunction or internal defect. Check it directly.
(2) When swing holding brake is released
When swing holding brake release switch is in emergency position, swing holding brake is released
and upper structure is secured only by oil pressure.
Cause
1
Possible causes
and standard
value in normal
state

valve (spool)

Seal of spool of swing control valve may be defective. Check it
directly.

Seal of pressure compensation valve section of swing control valve

may be defective. Check it directly.

motor (safety valve)
Seal of safety valve of swing motor may be defective. Check it directly.

Seal of suction valve of swing motor may be defective. Check it directly.

motor (check valve)
Seal of check valve of swing motor may be defective. Check it directly.
Malfunction of defective seal

Shockless valve of swing motor may have malfunction or defective
6 of swing motor (shockless
seal. Check it directly.
valve)
32
PC400, 450-7E0
40 Troubleshooting
SEN03605-00
H-30 Attachment circuit is not changed
When attachment is installed

Trouble
Related
information
Attachment circuit is not changed.

On a machine equipped with attachment, service circuit is changed as follows according to selected
working mode.
1) When P- or E-mode is selected: Double acting circuit is selected, setting safety valve to low-pressure set.
2) When B-mode is selected: Single acting circuit is selected, setting safety valve to high-pressure
setting.
* B port alone allows changing the set of safety valve. The valve remains constantly at low-pressure
set on A port side.
Cause

a
Possible causes
and standard
value in normal
state
Malfunction of service return

solenoid valve
Prepare with engine stopped, then run engine at high idle and
Working mode
P- or E-mode
0 MPa {0 kg/cm2}
B-mode
2.84 3.43 MPa

{29 35 kg/cm2}
Malfunction of service return Service return selector valve may have malfunction. Check it
valve
directly.
Malfunction of service control Safety valve (B port side) of service control valve may have malvalve (safety valve)
function. Check it directly.
H-31 Oil flow in attachment circuit cannot be controlled
When attachment is installed

Trouble
Related
information
Oil flow in attachment circuit cannot be controlled.

On a machine equipped with attachment, flow rate in service circuit changes depending on the mode
chosen from select mode.
Procedure for adjusting flow rate is not identical between P- or E-mode and B-mode. For more information, see Operation and Maintenance Manual.
Cause
1
Possible causes
and standard
value in normal
state
PC400, 450-7E0
Malfunction of service
current EPC valve

Service current EPC valve may have malfunction. Check it directly.
a
Malfunction of service PPC

2
valve
Prepare with engine stopped, then run engine at high idle and
Harness connector
Service pedal
PPC valve output

pressure
Disconnect V30 connector of service current EPC valve.
At neutral
0 MPa {0 kg/cm2}
Operated
2.75 MPa
{28 kg/cm2}
33
SEN03605-00

2008 KOMATSU
All Rights Reserved
34
SEN03606-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
40 Troubleshooting

Method of using troubleshooting chart............................................................................................................ 4
S-1 Starting performance is poor .................................................................................................................... 8
S-2 Engine does not start ............................................................................................................................. 10
S-3 Engine does not pick up smoothly.......................................................................................................... 14
S-4 Engine stops during operations .............................................................................................................. 15
S-5 Engine does not rotate smoothly ............................................................................................................ 16
S-6 Engine lacks output (or lacks power) ..................................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 19
S-9 Oil becomes contaminated quickly ......................................................................................................... 20
S-10 Fuel consumption is excessive............................................................................................................. 21
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 22
S-12 Oil pressure drops ................................................................................................................................ 23
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 24
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 26
S-15 Abnormal noise is made....................................................................................................................... 27
PC400, 450-7E0
SEN03606-00
40 Troubleshooting
S-16 Vibration is excessive ........................................................................................................................... 28
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03606-00
SEN03606-00
Method of using troubleshooting chart
40 Troubleshooting
The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with
When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03606-00
SEN03606-00
40 Troubleshooting
<Example of troubleshooting> Exhaust smoke is black

Let us assume that when Color of exhaust gas is black occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in Step 1 to Step 3 in the figure below to narrow
the [causes] to lead to [troubleshooting].
PC400, 450-7E0
SEN03606-00
40 Troubleshooting
S-1 Starting performance is poor
General causes why starting performance is poor
Q Q w w
Q Q
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck, seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter, strainer
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Defective contact of valve and valve seat
Clogged air cleaner element
E E
E
w
Q Q Q Q
w
w w Q Q
w
w
w w
w
w
w
Q
w Q Q
Q
w
w w
w
w
Q Q
w
Q w Q Q
q
q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
q
Clean
Replace
Correct
Inspect air cleaner directly

q
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows out
q
(*1)
When compression pressure is measured, it is found to be low
q q
When air is bled from fuel system, air comes out
Inspect fuel filter, strainer directly
Inspect gauze filter of feed pump directly
Carry out troubleshooting for Rail Press (Very) Low Error. (*2) See *2 for failure
code.
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage 20 30 V between alternator terminal R and terminal E with Yes
engine at low idle?
No
When specific gravity of electrolyte and voltage of battery are measured, they are low
Remedy
E E
Correct
Confirm recent repair history

Degree of use of
Operated for long period
machine
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally
(if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does
While engine is cranked not flow out
with starting motor
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Cracked EGR cooler (Coolant in exhaust piping)
The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly, even if the starting operation is carried out, the engine may not start until the crankshaft revolves 2 turns
at maximum. This phenomenon does not indicate a trouble, however.
Replace
Troubleshooting
Check items
Questions
Defective electrical system

Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
Coolant in exhaust piping
Clean
Cause
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
*2: Failure codes [CA559] and [CA2249]
PC400, 450-7E0
SEN03606-00
40 Troubleshooting
S-2 Engine does not start
a) Engine does not turn
Cracked EGR cooler (Coolant in exhaust piping)

Broken flywheel ring gear
Defective or deteriorated battery
Defective connection of battery terminal
Defective battery relay
Defective starting motor (safety relay section)
Defective starting motor (motor section)
Defective starting circuit wiring
Defective hydraulic pump
Cause
General causes why engine does not turn

Internal parts of engine seized:
See S-4 Engine stops during operations
Coolant entered in cylinder, producing water hammer
Defective electrical system
Degree of use of
machine
EEE
Condition of horn
Horn does not sound
when starting switch
Horn volume is low
is turned ON
Battery electrolyte is low
w
Q
When starting switch is turned to START, starting pinion does not move out
Q
Q
Speed of rotation is low

When starting switch
is turned to START, Makes grating noise
starting pinion moves Soon disengages again
out, but
Makes rattling noise and does not turn
w
w
w
w
Q w
q
q
Inspect flywheel ring gear directly

Troubleshooting
When specific gravity of electrolyte and voltage of battery are measured, they are
low
There is not voltage (20 30 V) between battery relay terminal M and terminal E
When terminal B and terminal C of starting switch are connected, engine starts
When terminal B and terminal C at safety relay outlet are connected, engine starts
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start
Remedy
q
q
q
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Check items
When starting switch is turned ON, there is no operating sound from battery relay
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
out (*1)
10
Battery terminal is loose
Turn starting switch

OFF, connect cord,
and carry out troubleshooting at ON
Carry out troubleshooting in E-mode

Carry out troubleshooting in H-mode
Questions
PC400, 450-7E0
40 Troubleshooting
SEN03606-00

PC400, 450-7E0
11
SEN03606-00
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust smoke comes out
Fuel is not being supplied
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Use of improper fuel

Insufficient fuel in tank
Clogged fuel filter element
Seized, abnormally worn feed pump
Broken supply pump shaft key
Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (Does not close)
Malfunction of flow damper
Defective fuel injector
Cause
Questions

Degree of use
of machine
EEE
w Q w w w
Exhaust smoke suddenly stopped coming out (when starting again)

Replacement of filters has not been carried out according to Operation
and Maintenance Manual
When fuel tank is inspected, it is found to be empty
Q w
Rust and water are found when fuel tank is drained

w
Q Q Q
Q Q
w Q Q
If air bleeding plug of fuel filter is removed, fuel does

While engine is not flow out
cranked with
If spill hose from injector is disconnected, little fuel
starting motor
spills
w Q
w w w w
q q
Inspect fuel filter directly

Troubleshooting
Inspect feed pump directly

Carry out troubleshooting for Rail Press (Very) Low Error. (*1)
See *1 for failure code.
Carry out troubleshooting for PCV1 Error (*2) or PCV2 Error (*3).
See *2 or *3 for failure code.
q
q
q
Inspect overflow valve directly
q q
Engine can be started in reduced cylinder mode

Remedy
Replace
Add
Correct
Correct
Replace
Clean
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Check items
When fuel filter is removed, there is not fuel in it
w w
EE

12
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
c) Exhaust smoke comes but engine does not start

(fuel is being injected)
General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system

Degree of use of
machine
Suddenly failed to start
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
When fuel filter is removed, there is not fuel in it
Starting motor cranks engine slowly
When engine is cranked, abnormal sound is generated around cylinder head
If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
cranked with starting out
motor
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low
E
w
E
w
Q Q
w w
w
w
w
Q
w w
w
w
w Q Q
w
w
Q
w w
w
w

q
Inspect dynamic valve system directly
q
q
Carry out troubleshooting for Rail Press (Very) Low Error. (*1) See *1 for failure code.
When injector is tested alone, condition of spray is poor
When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally (if the gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Remedy
EE
q
q
q
q
q
q
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace
Troubleshooting
Check items
Questions

Worn dynamic valve system (Valve, rocker lever, etc.)
Excessive wear of piston ring, cylinder liner
Leaking or clogged fuel system, entry of air
Clogged injector, defective spray
Defective, deteriorated battery
Defective coolant temperature sensor, wiring harness
Defective intake air heater system
Cause

PC400, 450-7E0
13
SEN03606-00
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly
Clogged injector, defective spray
EE
Q Q
w w w
Q
w
w w
w
w w
w
w Q Q
Q
Malfunction of flow damper (Leakage from injector is large)
w
w

q
Carry out troubleshooting for EGR Valve Servo Error. (*1) See *1 for failure code.
q
q
q
Inspect valve clearance directly
q
When turbocharger is rotated by hand, it is found to be heavy
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
Remedy
Seized turbocharger, interference of turbocharger
Improper valve clearance
EEE
w w
Q w
q
q q
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Correct
Questions
Check items
Troubleshooting

Degree of use of
machine
Engine pick-up suddenly became worse
Blue under light load
Color of exhaust
gas
Black
When engine is cranked, interference sound is generated around turbocharger
High idle speed under no load is normal, but speed suddenly drops when load is
applied
Stuck EGR valve

Defective condition of fuel injection
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)
EGR valve is stuck and is open
(Excessive EGR gas, insufficient intake of air)
Cause

14
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-4 Engine stops during operations
Broken supply pump shaft key
Broken, seized feed pump
Leaking, clogged fuel piping
Broken, seized gear train
Broken, seized crankshaft bearing

Degree of use of
machine
Abnormal noise was heard and engine stopped suddenly w w w w
w Q
Condition when engine Engine overheated and stopped
stopped
Engine stopped slowly
There was hunting and engine stopped
Fuel level monitor indicates low level (if monitor is installed)
Metal particles are found when oil pan is drained
w w w
Does not turn at all
w w
w
When engine is cranked Turns in opposite direction
by hand
Moves by amount of gear backlash
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine
EE
Q w Q w
w
w Q
Q Q
Q Q Q
Q Q Q
w w
w
w
w
w Q Q
w w
Q Q
Inspect piston, connecting rod directly

Troubleshooting
Broken, seized piston, connecting rod
Seized parts inside engine

There is overheating
Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Carry out troubleshooting in H-mode
Check items
Questions
Cause
Broken dynamic valve system (valve, rocker arm, etc.)
General causes why engine stops during operations
Inspect crank shaft bearing directly
Inspect gear train directly
Inspect feed pump directly

Carry out troubleshooting for Rail Press (Very) Low Error. (*1) See *1 for code.
Remedy
q q
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
PC400, 450-7E0
15
SEN03606-00
40 Troubleshooting
S-5 Engine does not rotate smoothly
Air in fuel system

Defective speed sensor (Error at degree that it is not indicated)
Defective EGR valve
Defective bypass valve

Degree of use of
machine
Occurs at a certain speed range
Occurs at low idle
Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according to Operation and
Maintenance Manual
Q
Q Q Q Q Q Q
Q
Q
w
Q
Q
Q
Q
Q
w w
w
Q Q
w
w Q Q

does not change
Carry out troubleshooting for Eng Ne Speed Sensor Error. (*3) See *3 for
failure code.
Carry out troubleshooting for Eng Bkup Speed Sensor Error. (*4) See *4 for failure
code.
Remedy

*2: Failure codes [CA1628] and [[CA1629]
*3: Failure code [CA689]
*4: Failure code CA778]
EE
Carry out troubleshooting for Bypass Valve Servo Error. (*2) See *2 for failure code.
Troubleshooting
Q Q Q
w
Q Q

16
EE
q
q
q
q
q
q q
q
q
Correct
Replace
Replace
Add
Clean
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Check items
Questions
Cause
Low idle speed is set too low
Malfunction of EGR valve
Malfunction of bypass valve
Malfunction of flow damper (Leakage from injector is large)
Clogged injector, defective spray (dirt in injector)
Defective Ne speed sensor, wiring harness
Defective Bkup speed sensor, wiring harness
General causes why engine does not rotate smoothly
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output
E
Q
E E
Q Q
Q Q
PC400, 450-7E0
Defective fuel temperature sensor, wiring harness
Defective charge air pressure sensor, wiring harness
Defective installation of charge air pressure sensor (air leakage)
Defective drive of injector (signal, solenoid)
Clogged injector, defective spray (dirt in injector)
Q
Q
Q Q Q
Q
w
Q Q Q
w Q
w w
w
w w
Q
w w Q
q
q q
q
q
Replace
Replace
Correct
Replace
Replace
Correct
q
Clean
Replace
Adjust
Replace
Replace
Replace
Q Q
Q Q Q Q
Clean
w w
Correct


q
Inspect air intake piping directly
q
When boost pressure is measured, it is found to be low
q q q
q
q
q
does not change
Inspect boost pressure sensor mount directly
Carry out troubleshooting for Chg Air Press Sensor High (Low) Error. (*2) See
*2 for failure code.
Carry out troubleshooting for Fuel Temp Sensor High (Low) Error. (*3) See *3
for failure code.
Remedy
Leaking, clogged fuel piping
E
Q w
Replace
Suddenly
Power was lost
Gradually
Maintenance Manual
Output becomes insufficient after short stop of operation
Black
Color of exhaust gas
High idle speed is too low
High idle speed under no load is normal, but speed suddenly drops when load is
applied
Clean
Questions
Check items
Troubleshooting

Degree of use of
machine
Air leakage from air intake piping

Defective condition of fuel spray
There is overheating:
See S-14 Coolant temperature becomes too high (Overheating)
Cause
17
SEN03606-00
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black
E
w
Q
w
w Q
w
Q
w
Q
Improper fuel injection pressure
Improper fuel injection timing
Clogged spill piping (on cylinder head side)
Abnormally worn injector
Clogged, seized injector
E
Q Q
Q Q
Q Q
Q Q
w
Q Q Q
Q w
w
Q Q
w
Q Q Q
q
q
q
q
q
Replace
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
q
Correct
Adjust
Replace
Replace
Replace
Q
Q w
Replace
Q
Q Q

q
q
q
q
q
When muffler is removed, exhaust gas color improves
Carry out troubleshooting for Rail Press (Very) Low Error. (*2) See *2 for
failure code.
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change
Inspect spill piping (on cylinder head side) directly
Carry out troubleshooting for Coolant Temp Sens High (Low) Error. (*3)
See *3 for code.
Remedy
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
Stuck EGR valve
E E
Clean
Check items
Troubleshooting

Degree of use of
machine
Suddenly became black
Color of exhaust
Gradually became black
gas
Oil must be added more frequently
Suddenly
Power was lost
Gradually
Muffler is crushed
Air leaks between turbocharger and cylinder head, clamp is loosened
Engine is operated in low-temperature mode at normal temperature
Torque converter stall occurred or pump relief speed is high (Fuel is injected
excessively)
Exhaust noise is abnormal
If spill hose from injector is disconnected, abnormally much fuel spills

Supply of fuel is excessive
Defective condition of fuel spray
There is overheating:
See S-14 Coolant temperature becomes too high (Overheating)
EGR valve is stuck and is open
(Excessive EGR gas, insufficient intake of air)
Questions
Cause

18
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
Abnormal consumption of oil

Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
External leakage of oil
Wear of parts in lubrication system
Dust sucked in from intake system

Worn, damaged valve (stem, guide, seal)
Worn seal at turbocharger end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve system
Clogged breather, breather hose
Broken piston ring
Worn, damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Oil leakage from oil pan, cylinder head, etc.
Cause
Questions

Degree of use of
machine
EEEE
E
w
Oil consumption suddenly increased

Q
Q
w
Q Q w
Oil becomes contaminated quickly
w w w w w
Outside of engine is dirty with oil

w
There are loose piping clamps in intake system
w
Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant

w
Oil level in damper chamber is high

Q
Exhaust smoke is blue under light load

Amount of blow-by
gas
Excessive
Troubleshooting
w w
w
None
q
When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be dirty abnormally
q
q q
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with oil
q
q
Check breather and breather hose directly

q q
q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q q
There is external leakage of oil from engine

Remedy
PC400, 450-7E0
w w
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Correct
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
19
SEN03606-00
40 Troubleshooting
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly
Defective seal at turbocharger turbine end

Worn EGR valve guide
Worn valve, valve guide
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad
Cause
Entry of exhaust gas into oil due to internal wear

Clogging of lubrication passage
Use of improper oil
Operation under excessive load
Degree of use of
machine
EEEE

Q
Oil filter clogging monitor indicates error even when oil temperature is high (if monitor is installed)
w Q
Metal particles are found when oil filter is drained
Q Q
Inside of exhaust pipe is dirty with oil
w
w

Amount of blow-by gas
Black
Q
Excessive
Troubleshooting
Q
w
Excessive play of turbocharger shaft
When EGR valve is removed, exhaust port is found to be dirty with oil
q q
Check breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly

Remedy
20
Q w
None
Replace
Replace
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Check items
Engine oil temperature rises quickly
See S-7
Questions
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-10 Fuel consumption is excessive
1
Cause
Fuel leakage inside head cover
Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail fuel pressure
Defective spray by injector
Defective operation of injector
General causes why fuel consumption is excessive

Leakage of fuel
Defective condition of fuel injection (fuel pressure, injection timing)
Excessive injection of fuel
Questions

Degree of use of
machine
Condition of fuel consumption
EE
E
Q
More than for other machines of same model

Q
Gradually increased
Suddenly increased
Q Q
There is external leakage of fuel from engine
w
w
Combustion is irregular
w

Low idle speed is high
Torque converter stall occurred or oil pressure pump relief speed is high
Q Q
Black
Q Q
White
Remove and inspect head cover directly
Inspect feed pump oil seal directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q
q
If spill hose from injector is disconnected, much fuel spills

Carry out troubleshooting for Coolant Temp Sens High (Low) Error. (*2) See *2 for failure code.
q
q
Check with monitoring function of the machine monitor.

Remedy
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q
Q

PC400, 450-7E0
21
SEN03606-00
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Cause
Broken cylinder head, head gasket
Cracks inside cylinder block
Broken O-ring of cylinder liner, holes caused by pitting
Insufficient amount of thrust by cylinder liner
Broken oil cooler core, O-ring
General causes why oil is in coolant

Internal leakage in lubrication system
Internal leakage in cooling system
Questions

Degree of use of machine
Increase of oil level

Q
Suddenly occurred
Oil level has risen, oil is milky
There are excessive air bubbles in radiator, coolant spurts back
Pressure-tightness test of cylinder head shows there is leakage
Q Q
q q
Inspect cylinder block, liner directly
Inspect cylinder liner directly
Remedy
Replace
Replace
Replace
Replace
Replace
Troubleshooting Check items
Q
Q Q
Gradually occurred
Hard water is being used as coolant
22
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-12 Oil pressure drops
Cause
Worn journal of bearing
Lack of oil in oil pan
Coolant, fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump
Leakage from EGR oil pressure piping
Defective oil pressure sensor, wiring harness
Defective oil level sensor, wiring harness
General causes why oil pressure drops

Leakage, clogging, wear of lubrication system
Defective oil pressure control
Improper selection of oil (improper viscosity)
Deterioration of oil due to overheating
Questions

Degree of use of
machine
E
Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q
Non-specified oil is being used
Maintenance Manual
Check items
Oil pressure
monitor
(if monitor is
installed)
w
w
Indicates pressure drop at low idle
Indicates pressure drop at low, high idle
Indicates pressure drop on slopes
w w w Q
Q Q
Sometimes indicates pressure drop
Oil level monitor indicates oil level drop (if monitor is installed)
Oil level in oil pan is low
Q Q
w
w
External hydraulic piping is leaking, crushed
Oil is milky or smells of diesel oil

Metal particles are found in oil filter
q q
Inspect oil pan strainer, pipe directly
Oil pump rotation is heavy, there is play in oil pump

See S-13
Valve spring of oil pump relief valve is fatigued, damaged

Inspect oil filter directly
Relief valve of EGR oil pump is damaged, leaks oil
Inspect EGR oil pressure piping directly
Carry out troubleshooting for Eng Oil Press Sensor High (Low) Error. (*1)
See *1 for failure code.
If oil level sensor is replaced, oil pressure monitor indicates normally
Remedy
q
q
q
q
q
q
Replace
Add
Clean
Clean
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace
Troubleshooting
PC400, 450-7E0
23
SEN03606-00
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel)
1
Cause
Cracked EGR cooler (Coolant in oil)
Fuel leakage inside head cover
Cracks inside cylinder block
Worn, damaged rear oil seal
Broken oil cooler core, O-ring
Clogging or defective seal of water pump drain hole (breather hole)
Defects in thermostat seat section
Defects in supply pump
Defective seal of accessories (Pump, compressor)
General causes why oil level rises

Degree of use of
EE
E
machine
Fuel must be added more frequently
w
w
Coolant must be added more frequently
Q Q
w
There is oil in coolant
Q
Q Q
w
Oil smells of diesel fuel
w
w
Oil is milky
Q Q
w
When engine is started, drops of water come from muffler
Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number
w
Q
of bubbles appear, or coolant spurts back
Exhaust smoke is white
Q
Q
Water pump drain hole (breather hole) is clogged
w
When water pump drain hole (breather hole) is cleaned up, water comes out
w
Oil level in clutch or damper chamber of machine is low
w
Oil level in hydraulic tank is low
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze
flows out (*1)
Remove and inspect head cover directly
Inspect cylinder block, liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect thermostat cover directly
Remove and inspect supply pump directly
Inspect seal of accesories directly
Remedy
24
q
q
q
q q
q
q
q
q
q
q
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Replace
Troubleshooting
Check items
Questions
Coolant in oil (milky)

Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
PC400, 450-7E0
40 Troubleshooting
SEN03606-00

PC400, 450-7E0
25
SEN03606-00
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Clogged, broken oil cooler
Lack of cooling air (deformation, damage of fan)

Drop in heat dissipation efficiency
Problem in coolant circulation system
Rise in hydraulic oil temperature
External water leakage from EGR cooler
Cause
General causes why coolant temperature becomes too high
Questions

Degree of use of
machine
EEE
Condition of over- Suddenly overheated

heating
Always tends to overheat
EE
Q w
Q
Q w w
Coolant tempera- Rises quickly

ture gauge
Does not go down from red range
(if installed)
w
w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed)
w
w Q
Engine oil level has risen and oil is milky
Fan belt tension is low
When fan belt is turned, it has play
Check items
Milky oil is floating on coolant
There are excessive air bubbles in radiator, coolant spurts back

When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged

with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration
Inspect EGR cooler for leakage of coolant directly
q
q
Inspect oil cooler directly

Temperature difference between upper and lower tanks of radiator is large
When operation test of thermostat is carried out, it does not open at cracking temperature
Temperature difference between upper and lower tanks of radiator is slight
q
q
q
Inspect radiator core directly

When operation of radiator cap is carried out, its cracking pressure is low
q
q
Inspect fan belt, pulley directly
When coolant temperature is measured, it is fount to be normal

Remedy
26
Replace
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Correct
Replace
Troubleshooting
Inspect cylinder liner directly
PC400, 450-7E0
40 Troubleshooting
SEN03606-00
S-15 Abnormal noise is made
General causes why abnormal noise is made
Troubleshooting
Check items
Questions

Degree of use of Operated for long period
E
machine
Gradually occurred
Q
Q
Condition of
abnormal noise
Suddenly occurred
Q Q Q
Q
w
w
w
Air leaks between turbocharger and cylinder head
w
w
When engine is cranked, abnormal sound is generated around EGR gas piping
w
w
w
When engine is cranked, beat noise is generated around muffler
w
w
Color of exhaust
gas
Black
Q w
Q
Engine does not pick up smoothly and combustion is abnormal
Abnormal noise is loud when engine is accelerated
Q
Q
Q
w
Inspect EGR gas piping directly
When muffler is removed, abnormal noise disappears
Inspect fan and fan belt directly
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
Abnormal noise is heard only when engine is started
Check with monitoring function of the machine monitor
Remedy
PC400, 450-7E0
q
q
q
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized gear train bushing
Improper gear train backlash
Defective inside of muffler (dividing board out of position)
Broken dynamic valve system (valve, rocker lever)
Crack of or gas leakage from EGR gas piping
Interference of turbocharger, seized turbocharger
Judge if the noise is an internal noise or an external noise before starting

troubleshooting.
The engine is operated in the low-temperature mode while it is not
warmed up sufficiently. Accordingly, the engine sound becomes a little
larger. This does not indicate abnormality, however.
When the engine is accelerated, it is operated in the acceleration mode
and its sound becomes a little larger for up to about 3 seconds. This does
not indicate abnormality, however.
w Q
w
Q
q
q q
q
q q
q
q
Replace
Replace
Replace
Correct
Replace
Adjust
Replace
Replace
Replace
Correct
Replace
Correct
Correct
Leakage of air between turbocharger and cylinder head
Abnormality due to defective parts

Abnormal combustion
Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant low temperature sensor)
Cause
27
SEN03606-00
40 Troubleshooting
S-16 Vibration is excessive
1
Cause
Defective parts (abnormal wear, breakage)

Misalignment between engine and chassis
Abnormal combustion
a
If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever)

Worn main bearing, connecting rod bearing
Improper gear train backlash
Worn camshaft bushing
Loose engine mounting bolts, broken cushions
Misalignment between engine and devices on machine side
Broken parts inside damper
General causes why vibration is excessive
Degree of use of
machine
Condition of
vibration
Suddenly increased
Q
Q
Gradually increased
Oil pressure is low at low idle
Vibration occurs at mid-range speed

Q
Vibration follows engine speed

Exhaust smoke is black
Q Q Q
Q
Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
Check with monitoring function of machine monitor
Inspect engine mounting bolts and cushions directly

When alignment is measured, radial runout or facial runout is detected
q
q
Inspect inside of damper directly

Remedy
28
Replace
Replace
Replace
Replace
Adjust
Replace
Adjust
Correct
Troubleshooting
Check items
Questions
PC400, 450-7E0
40 Troubleshooting
PC400, 450-7E0
SEN03606-00
29
SEN03606-00

2008 KOMATSU
All Rights Reserved
30
SEN03608-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools ...............................................................................................................................11
PC400, 450-7E0
SEN03608-01
How to read this manual

1.
Removal and installation of assemblies

Special tools
q
Special tools which are deemed necessary for removal or installation of parts are
described as A1,X1 etc. and their part
names, part numbers and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
(installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They respectively have a
new part number.
R:
Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
* *** ****
General tools that are necessary for

removal or installation are described as
[1],[2]etc. and their part names, part
numbers and quantities are not described.
Removal
q
The [Removal] section contains procedures
and precautions for implementing the work,
know how and the amount of oil or coolant to
be drained.
q
Various symbols used in the Removal Section
are explained and listed below.
k : This mark indicates safety-related precautions that must be followed when implementing the work.
a: Know-how or precautions for work
[*1] : This mark shows that there are instructions or
precautions for installing parts.
6 : This mark shows the amount of oil or coolant
to be drained.
4 : Weight of part or component
Installation
q
Except where otherwise instructed, installation
of parts is done in the r evers e order of
removal.
q
Instructions and precautions for installing parts
are shown with [*1] mark in the Installation
Section, identifying which step the instructions
are intended for.
q
Marks shown in the Installation Section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools

q
Various special tools are illustrated for the convenience of local manufacture.
PC400, 450-7E0
2.
Disassembly and assembly of assemblies
SEN03608-01
Disassembly
In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q
The meanings of the symbols used in Disassembly section are as follows.
k : This mark indicates safety-related precautions that must be followed when implementing the work.
a : Know-how or precautions for work
6: Quantity of oil or coolant drained
q
Special tools
q
Special tools which are deemed necessary for removal or installation of parts are
described as A1,X1 etc. and their part
names, part numbers and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
(installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N
: Tools newly developed for this
model. They respectively have a
new part number.
R
: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
* *** ****
Assembly
q
In Assembly section, the work procedures, precautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q
The meanings of the symbols used in Assembly section are as follows.
k : Precautions related to safety in execution
of work
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added

Various special tools are illustrated for the convenience of local manufacture.
General tools that are necessary for

removal or installation are described
as [1],[2]etc. and their part names,
part numbers and quantities are not
described.
PC400, 450-7E0
SEN03608-01
Coating materials list

a
a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
Can
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Aron-alpha
201
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
ThreeBond
1735
1 kg
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
Tube
Used to stick or seal gaskets and packings of

power train case, etc.
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-6
790-129-9020
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
(Rev. 2007.06)
1
419-15-18131
100 g
PC400, 450-7E0
Seizure
prevention
compound
Molybdenum
disulfide
lubricant
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-9
ThreeBond
1206D
790-129-9310
200 g
Tube
Used for rough surfaces such as the circle gear

top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LM-P
LC-G
NEVER-SEEZ
09940-00040
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
Grease
SEN03608-01
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
G2-U-S
ENS grease
PC400, 450-7E0
427-12-11871
200 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
200 g
2 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SEN03608-01
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
417-926-3910
22M-54-27230
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
PC400, 450-7E0
SEN03608-01
Special tools list
Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
t ........... Cannot be substituted, must always be installed (used)

q ........... Extremely useful if available or can be substituted with commercially available
part
New/Remodel: N............ Tools with new part numbers, newly developed for this model
R:........... Tools with upgraded part numbers, remodeled from items already available for
other models
Blank: ... Tools already available for other models, can be used without any modification
Standard puller
Fuel supply pump
2 01010-81080
Bolt
Part name
3 01643-31032
Washer
Front and rear oil

seal
4 795-931-1100
Seal puller assembly
Front oil seal
5 01010-61650
Push tool
Bolt
01643-31645
Washer
795T-421-1340
Push tool
Bolt
01643-31645
Washer
795-931-1220
Push tool
Bolt
01643-31645
Washer
795T-421-1320
Push tool
Bolt
01643-31645
Washer
Angle tightening of
bolt
9 790-331-1110
Wrench
Engine valve
clearance
10 795-125-1360
Clearance gauge
796T-601-1110
Stopper
796-460-1210
Oil stopper
796-770-1320
Adapter
795T-521-1140
6 01010-61635
A
7 01010-61650
Rear oil seal
8 01010-61645
Engine and
hydraulic pump
assembly
PC400, 450-7E0
B
C
Sketch
1 795-630-5500
Part number
New/remodel
Component
Q'ty
Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
Necessity
Symbol
Necessity:
Nature of work, remarks
Removal of fuel supply pump

Removal of front and rear oil
seal
N
Q
Press fitting of oil seal
Press fitting of standard oil seal

(with guide)
Press fitting of sleeved oil seal
Adjustment of engine valve

clearance
N
Removal, installation of engine

mounting bolt
Stopping of oil
Swing motor and

swing machinery
assembly
Q'ty
Push tool
2 790-201-2350
Push tool
Removal of bearing
3 790-201-2510
Press fitting of bearing
4
D
Push tool
790-101-5401
Push tool kit
790-101-5531
Plate
790-101-5421
Grip
01010-51240
Bolt
Idler assembly
Press fitting of bearing inner

race
6 790-201-2770
Push tool
Press fitting of bearing inner

race
7 796T-626-1110
Push tool
796-627-1210
Wrench assembly
796-627-1220
Wrench
796-427-1140
Pin
01314-20612
Screw
796T-627-1230
Push tool
790-101-2510
Block
791-122-1130
Plate
790-101-2550
Leg
Adapter
Plate
790-101-2560
Nut
790-101-2102
Puller (294 kN {30 t})
790-101-1102
Pump
3 796-627-1020
Installer
791-430-3230
Installer
791-601-1000
Oil pump
791-630-1780
Installer
791-601-1000
Oil pump
791-575-1520
Installer
791-601-1000
Oil pump
791-685-8006
Compressor
791-635-3160
Extension
790-101-1600
Cylinder
(686 kN {70 t})
790-101-1102
Pump
790-201-1500
Push tool kit
790-201-1660
Plate
790-101-5021
Grip
01010-50816
Bolt
1
Recoil spring
assembly
Press fitting of oil seal
790-101-2570
Track roller
assembly
Q Removal of shaft
2 790-101-2740
Push tool
Carrier roller
assembly
Part name
5 790-201-2870
Final drive
assembly
Part number
Sketch
Necessity
1 796T-627-1630
Symbol
Component
New/remodel
SEN03608-01
Q Press fitting of bearing

Removal, installation of round
nut
Q
Pressing of bearing inner race
Installation of floating seal
Supply of oil
Disassembly, assembly of
recoil spring assembly
Installation of dust seal
PC400, 450-7E0
Track shoe
assembly
Remover and installer
790-101-1300
Cylinder
(980 kN {100 t})
790-101-1102
Pump
796-946-1310
Guide 21.8
796-946-2110
Guide 20.9
Guide 20.6
(For 723-46-45100, 723-46-45500)

796-946-1320
Guide
(For 723-46-40100, 723-46-40601)

796-946-1420
Control valve
assembly
2
L
Guide 21.6
(For 723-46-42800)
796-946-2120
Guide
(For 723-46-44100)
796-946-2220
Guide
Sleeve
(For 723-46-40100, 723-46-40601)

796-946-1430
3
Sleeve
(For 723-46-42800)
796-946-2130
Sleeve
(For 723-46-44100)
796-946-2230
Sleeve
(For 723-46-45100, 723-46-45500)
Center swivel joint

assembly
PC400, 450-7E0
Replacement of pressure
compensation valve seal
(For 723-46-45100, 723-46-45500)

796-946-1330
Pulling out of master pin
(For 723-46-44100)
796-946-2210
(For 723-46-40100, 723-46-40601)

1
Sketch
791-650-3000
Part number
New/remodel
Part name
Q'ty
Component
SEN03608-01
Necessity
Symbol
790-101-2501
Push puller
790-101-2510
Block
1
1
790-101-2520
Screw
791-112-1180
Nut
790-101-2540
Washer
790-101-2630
Leg
790-101-2570
Plate
790-101-2560
Nut
790-101-2650
Adapter
Disassembly, assembly of center swivel joint assembly
790-102-4300
Wrench assembly
790-102-4310
Pin
Expander
Ring (For boom and

bucket)
Clamp (For boom and

bucket)
Ring (For arm)
07281-01919
Clamp (For arm)
790-201-1702
Push tool kit
790-201-1851
Push tool
(For bucket)
790-201-1861
Push tool
(For boom)
790-201-1871
Push tool (For arm)

120
790-101-5021
Grip
1 790-502-1003
2
3 790-720-1000
796-720-1680
4 07281-01589
796-720-1690
Hydraulic cylinder
assembly
N
5
Travel PPC valve

assembly
Operators cab
glass
10
Disassembly, assembly of
hydraulic cylinder assembly
Removal, installation of piston
assembly
Installation of piston ring
Press fitting of bushing
01010-50816
Bolt
790-201-1500
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
790-201-1660
Plate
(For bucket)
790-201-1670
Plate (For boom)
790-201-1680
Plate (For arm)
796-670-1100
Remover
796-670-1110
Sleeve
796-670-1120
Plate
796-670-1130
Screw
796-870-1110
Adapter
01643-33080
Washer
01803-13034
Nut
790-101-4000
Puller (490 kN {50t},

long)
790-101-1102
Pump (294 kN {30t})
1 796T-416-1010
Push tool
2 796T-416-1030
Push tool
3 796T-416-1020
Push tool
Q Installation of pin
1 793-498-1210
Lifter
(Suction cup)
2 20Y-54-13180
Adapter
Work equipment
assembly
Part name
Sketch
Cylinder repair stand
Part number
New/remodel
Q'ty
Component
Necessity
Symbol
SEN03608-01
1
t
Press fitting of dust seal
1
q
Removal of foot pin
Press fitting of bushing
Removal and Installation of

operators cab glass
PC400, 450-7E0
SEN03608-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A5. Push tool
A6. Push tool
PC400, 450-7E0
11
SEN03608-01
A8. Push tool
B. Stopper
12
PC400, 450-7E0
SEN03608-01
D1. Push tool
D7. Push tool
PC400, 450-7E0
13
SEN03608-01
E2. Push tool
Q1. Push tool
14
PC400, 450-7E0
SEN03608-01
Q2. Push tool
Q3. Push tool
PC400, 450-7E0
15
SEN03608-01

2008 KOMATSU
All Rights Reserved
16
SEN03609-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0
50 Disassembly and assembly1

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 6
Removal and installation of engine front seal ............................................................................................... 12
Removal and installation of engine rear seal ................................................................................................ 15
Removal and installation of cylinder head assembly .................................................................................... 19
Removal and installation of radiator assembly ............................................................................................. 28
Removal and installation of hydraulic oil cooler assembly ............................................................................ 30
Removal and installation of aftercooler assembly......................................................................................... 32
Removal and installation of engine and hydraulic oil pump assembly .......................................................... 33
PC400, 450-7E0
SEN03609-01
Removal and installation of fuel

supply pump assembly
1
1 795-630-5500
A 2 01010-81080
3 01643-31032
Standard puller
t 1
Bolt
t 2
Washer
t 2
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
8.
Disconnect return hose (8) of the fuel supply

pump.
9. Disconnect the intake air heater harness clamp
(9) and fuel supply pump connectors PV1 (10),
PV2 (11) and G (12).
10. Remove the fuel supply pump high-pressure
pipe clamp (13) and 2 boots (13A).
[*1]
a Common rail side not visible sheltered by
the fuel filter.
Removal
k
1.
2.
3.
4.
5.
Disconnect the negative () terminal of battery.

Open the engine inspection cover.
Remove undercover (radiator, engine).
Remove cover (1).
Remove fan guard (2).
Remove air intake hose (3).
11. Remove 2 high-pressure pipes (14) at the fuel
supply pump outlet port.
[*2]
6.
7.
Loosen adjustment nut (5) and locknut (6) and

remove V-belt (7) from the pulley.
Disconnect harness connector (M34), remove
the bracket mounting bolts, remove air conditioner compressor assembly (4) and deposit
them on the floor cover.
12. Disconnect inlet tube (15) of the fuel supply

pump.
[*3]
PC400, 450-7E0
13. Disconnect feed pump inlet tube (16) and outlet tube (17) to remove lubrication tube (18).
14. Remove fuel supply pump bracket (19) from

the engine bottom.
SEN03609-01
16. Remove nut (21) and washer (22).

a Take care not to drop the removed parts
into the gear case.
[*4]
17. Setting the tools

1) Insert the bar into the fan pulley round hole
(a) and rotate the crankshaft normally.
a Rotate by tightening the fan belt or
pressing hard on the mid section of
the V-belt.
15. Remove cover (20) on the side of timing gear

case.
PC400, 450-7E0
SEN03609-01
2)
Align the tapped hole (hole for inserting

the removal bolt) of supply pump drive
gear to the mounting bolt hole of the cover
(cover (20) removed in step 15).
a Rotate the crankshaft to about the
middle (a) between the damper 25TOP and 3-4TOP and then inch the
crankshaft until correctly aligned to
the bolt hole.
a If the tapped hole on the drive gear
does not appear, rotate the crankshaft
one more round.
3)
Set tools A1, A2 and A3.
18. Remove the fuel supply pump mounting bolts

(23). Press the shaft of the pump using a tool and
remove the fuel supply pump assembly (24). [*5]
a Take care not to drop the pump.
a Leave the tool applied until the pump is
installed next.
[*6]
PC400, 450-7E0
SEN03609-01
Installation
a
Carry out installation in the reverse order to

removal.
[*1]
Tighten clamp (13) with the hand first, and then
tighten it permanently.
3 Clamp mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
[*2]
Install high-pressure tube (14) by tightening by
hand, then tighten it permanently.
3 Sleeve nut of the high-pressure tube:
Common rail side:
39.2 58.8 Nm {4 6 kgm}
Pump side: 39.2 49 Nm {4 5 kgm}
a Face the common rail side slit of the splash
prevention cover downward and the supply
pump side slit toward the cylinder block.
[*3]
Joint bolt of tube (15):

25.5 34.3 Nm {2.5 3.5 kgm}
[*4]
Gear mounting nut:

127 147 Nm {13 15 kgm}
Match the key and keyway to install.
[*5]
Joint bolt of pump side:

24.5 34.3 Nm {2.5 3.5 kgm}
[*6]
Mounting bolt: Gasket sealant (LT-2)
Fuel leak check

Refer to the paragraph on the "Checking fuel
circuit for leakage in Testing and adjusting,
and check the fuel system for any leakage
accordingly.
Air bleeding
Refer to the paragraph on the "Bleeding air
from fuel circuit" in Testing and adjusting, and
bleed the air accordingly.
PC400, 450-7E0
SEN03609-01
Removal and installation of fuel

injector assembly
1
6.
Remove clamp (4) and remove air intake tube

(5).
[*1]
Remove the clamp and disconnect hose (9)

between the radiator and the engine at the
radiator side.
[*2]
Remove covers (6), (7), and fan guard (8).
Removal
1.
Drain coolant.
6
2.
Coolant: Approx. 36 l
Drain hydraulic oil.

6
Hydraulic oil: Approx. 248 l
3.
Close the fuel stopper valve on the fuel tank.
4.
Remove connector (P24), overflow tube (1)

and sub-tank (2).
7.
Remove the mounting bolt and then hoist the

engine hood assembly (3) to remove.
8.
5.
Engine hood: 200 kg
9.
Remove oil filter (10). (Leave the tube unremoved)
10. Remove fuel pre-filter (11).

(after disconnecting the hose, put it at the left
side of the engine)
11. Remove priming pump (12).
(after disconnecting the hoses, let each hose
put on the left-hand side of the engine)
PC400, 450-7E0
SEN03609-01
12. Remove fuel main filter (13).

(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine. [*3]
16. Remove clamp (23), bolts (24) and bracket (25)

to remove the housing complex (diffuser) (26).
13. Disconnect the terminal of intake air heater
harness (14).
a Disconnect the clamp.
14. Remove the air intake connector (15).
15. Disconnect the connector EGR (16), SEGR

(17), TIM boost temperature (18), wiring clamp
(19), PIM boost pressure sensor (20), PAMB
atmospheric sensor (21) and connector (22).
a Remove harness clamps.
a Place removed parts together under the
engine.
[*4]
PC400, 450-7E0
17. Disconnect injector harness connectors (27) (at 6

places), remove the clamp and shift the harness
to the lower left-hand side of the engine.
a For how to remove the connector, see the
Removal and installation of cylinder head
assembly.
18. Remove clamps (28) and boots (29).
19. Remove the clamp and 6 high-pressure injection tubes (30).
[*5] [*6]
SEN03609-01
20. Remove head cover (31).
[*7]
23. Remove holder mounting bolt (40) of injector

(39) and then remove injector (39) along with
holder (41).
[*11]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
21. Removal of injector harness.

[*8]
1) Fully loosen 2 capture nuts (33) on the
head of injector (32).
[*9]
a Loosen nuts alternately.
2) Loosen bolt (34) of harness fixing holder.
[*10]
22. Removal of rocker arm assembly (35).

1) Loosen locknut (36) and then loosen
adjustment screw (37).
2) Remove mounting bolt (38) and then
rocker arm and shaft assembly (35).
PC400, 450-7E0
Installation
a

removal.
[*1]
Hose clamp: 9.8 0.5 Nm {100 5 kgcm}
[*2]
Radiator-related hose clamp

(9): 8.8 0.5 Nm {0.9 0.05 kgm}
[*3]
Fuel filter joint bolt:

24.5 34.5 Nm {2.5 3.5 kgm}
[*4]
Keep the harness assembly and other harnesses 10
mm and above away from the high-pressure tube.
[*5]
k
k
Don't correct high-pressure tube by bending it for re-use.

Always use genuine clamp for fixing highpressure pipe. Strictly observe the tightening torque requirements.
Keep the harness assembly and other harnesses 10 mm and above away from the
high-pressure tube.
SEN03609-01
Install high-pressure tubes between the common rail and fuel injector according to the following instructions:
1) Install high-pressure pipes (70), (71), (72),
(73), (74) and (75).
a Mounting angle of the high-pressure
injection pipe is adjusted when the
injector is installed.
3 Sleeve nut (on both sides):
39.2 49 Nm {4 5 kgm}
2) Install bracket (76) and clamp (77) and
tighten by hand first, and then tighten
them permanently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
3) Install clamps (78), (79), (80) and (81).
4) Install 6 each splash prevention covers
(82) and (83).
a Direct the slit on the injector side
downward and that on the common
rail side toward the cylinder block.
[*6]
Check the following matters before installing highpressure pipe. If there is any abnormality, replace
the high-pressure tube to prevent possible fuel
leakage.
q
Check the taper seal portion (between the tip

of section (a) and 2 mm from the end) of the
joint section for any vertical slit (b) and/or dent
(c) visually recognizable.
Check part (d) (from the tip of the taper seal
portion to 2 mm from the end) for any stepped
wear (fatigue) your finger nail may catch.
PC400, 450-7E0
SEN03609-01
5)
6)
Install bracket (84).

3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Install clamps (78), (79), (80) and (81).
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
2)
Install gasket (91) and O-rings (92) and (93) to

injector (85).
2 O-ring: Engine oil (EO30)
3)
Insert holder (87) to injector (86). While holding

them in this state, insert inlet connector (90) to
the locker housing toward the high-pressure
pipe insertion hole.
4)
Fit the ball washer to bolt (88) and tighten

holder (87) temporarily.
2 Spherical part of washer:
Engine oil (EO30)
Locate high-pressure sleeve (89) to inlet connector (90) and then tighten them temporarily.
a Tighten the common rail side sleeve nut
temporarily, too.
Tighten holder (87) permanently using bolt
(88).
a Tighten bolt while pulling the tube of the
high-pressure pipe in the opposite direction to the injector.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the highpressure sleeve from the inlet connector and
then install the other injectors sequentially by
following the above procedure.
[*7]
Head cover mounting bolt

9.8 1 Nm {1.0 0.1 kgm}
[*8]
Capture nut: 2.0 2.4 Nm {0.2 0.24 kgm}
[*9]
Tighten the mounting bolt of harness holder.
3 Mounting bolt:
27.0 34.0 Nm {2.8 3.5 kgm}
[*10]
Tighten 2 harness capture nuts to the injector.
a Tighten the nuts alternately.
3 Mounting nut:
2.0 2.4 Nm {0.2 0.24 kgm}
[*11]
Check that the inside of the injector sleeve is free
from dirt.
1) Loosen the mounting bolt of common rail (85).
5)
6)
7)
10
PC400, 450-7E0
8)
Tighten the common rail mounting bolt.

3 Common rail mounting bolt:
59 74 Nm {6.0 7.5 kgm}
Feed coolant
Feed coolant from the radiator coolant filler to
the specified level. Start the engine and allow
the coolant to circulate the piping. Check the
coolant level.
5
SEN03609-01
Fuel leak check

Refer to the paragraph on the Checking fuel
circuit for leakage in Testing and adjusting
section, and check the fuel system for any
leakage accordingly.
Air bleeding
Refer to the paragraph on the Bleeding air
from fuel circuit in Testing and adjusting, and
bleed the air accordingly.
PC400, 450-7E0
11
SEN03609-01
Removal and installation of

engine front seal
5.
Remove fan (6).
6.
Remove fan belt (7) and the air compressor

belt (8).
[*1]
7.
Sling the damper and pulley assembly (9) and

then remove it by loosening 6 mounting bolts.
4 795-931-1100
A
Seal puller
assembly
795T-521-1140 Push tool

5 01010-61650
01643-31645
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
q 1
t 1 N Q
Bolt
t 3
Washer
t 9
Removal
1.
2.
3.
4.
12
See the paragraphs for the Removal and

installation of radiator, Removal and installation of hydraulic oil cooler, and Removal and
installation of aftercooler to remove the radiator, hydraulic oil cooler and the aftercooler.
Damper and pulley assembly: 25 kg
8.
Remove front seal.
Take care not to damage the seal fitting portion

of front cover (10) and the seal contact surface
of crankshaft (11).
Before pulling out the seal, drive in it a little to
separate.
If front seal (12) is sticking to front cover (10)
and cannot be removed easily, remove it
1) Drill several holes about 3 mm in diameter
into front seal (12).
2) Replace the tip of tool A4 with the drilltype tip.
3) Put the tip of tool A4 in one of the drilled
holes and remove the front seal with
impacts of slide hammer [1].
a Remove the front seal evenly so that
it will not slant.
a Remove all the chips so that they will
not enter the engine.
Remove covers (1) and fan guard (2).
Loosen the air compressor assembly mounting

bolts and loosen adjustment nuts (3).
Loosen alternator assembly adjustment nuts
(4) and adjustment bolt guide (5).
a
a
PC400, 450-7E0

a
Take care not to damage crankshaft

(11).
PC400, 450-7E0
SEN03609-01
Installation
Assembly procedure for front seal
a Check the rims of the crankshaft end, sliding
surfaces of the lip, and front cover for flaws,
burrs, rust, etc.
1. Install front seal (12) to front cover (10) and
press fit it with a plastic hammer until seal lip
(a) is inserted in crankshaft (11).
a Take care not to mistake the installed
direction of the front seal.
a While taking care not to damage the front
seal, hit its periphery evenly to press fit.
a Take care that the seal lip will not be
caught in the crankshaft.
2 Front seal lip (50 80% of space in lip):
Grease (G2-LI)
2.
Install tool A5 and tighten 3 bolts (A5-1) until

they stop to press fit front seal (12) to front
cover (10).
a Do not fit washers to bolts (A5-1).
3.
Remove 3 bolts (A5-1), fit 3 washers (A5-2)

each to them, and tighten them again evenly to
press fit front seal (12) until the end of tool A5
reaches the end of front cover (10).
a Press fitting distance (b) of front seal from
front cover end: 16 (+1/0) mm
13
SEN03609-01

removal.
[*1]
q
14
Adjust the belt tension. For details, see Testing and adjusting, Checking and adjusting fan
belt and alternator belt tension and Checking
and adjusting air conditioner compressor belt
tension.
PC400, 450-7E0
SEN03609-01

engine rear seal
4 795-931-1100
Seal puller
assembly
795T-421-1340 Push tool
t 1 N Q
Bolt
t 3
Washer
t 3
795-931-1220
Push tool
t 1
Bolt
t 3
Washer
t 3
7 01010-61650
01643-31645
795T-421-1320 Push tool

8 01010-61645
01643-31645
N/R
q 1
01643-31645
6 01010-61635
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Removal of standard seal

a Before pulling out the seal, drive in it a little to separate.
1) Drill several holes about 3 mm in diameter
into the rear seal.
2) Replace the tip of tool A4 with the drilltype tip.
3) Put the tip of tool A4 in one of the drilled
holes and remove the front seal with
impacts of slide hammer [1].
a Remove the rear seal evenly so that it
will not slant.
a Remove all the chips so that they will
not enter the engine.
t 1 N Q
Bolt
t 3
Washer
t 9
A6:
Press fitting of standard seal (with guide)
A7, A8: Press fitting of sleeved seal
Removal
1.
Remove hydraulic pump assembly by reading

the paragraph for the Removal and installation
of hydraulic pump assembly.
2.
Remove the damper.
3.
Sling the flywheel (2) by leaving a flywheel

mounting bolt (1) unremoved.
4.
Sling the flywheel (2) to remove.

4
5.
Flywheel assembly: 60 kg
Since the sling [1] is held slanted when

the flywheel is lifted, care be taken for
the swinging of sling when the flywheel
assembly (2) is released.
Removal of sleeved seal

1) Hitch the end of tool A4 to the metal ring
of rear seal (3) and pull out the seal with
impacts of a slide hammer [1].
a Before pulling out the rear seal, drive
in it a little to separate it from housing
(5) for the ease of removal.
2) Cut and remove sleeve (4) with a chisel
and a hammer.
a When cutting the sleeve, take care
extremely not to damage crankshaft
(6).
a Remove all the chips.
Removal of rear seal

a Take care not to damage the seal fitting
portion and crankshaft contact face of the
flywheel housing.
PC400, 450-7E0
15
SEN03609-01
Installation
q
1.
Set large inside diameter side (b) of guide (7)

rear seal (3) to the end of crankshaft (6).
a Take care not to mistake the installed
direction.
2.
Push the metal ring of rear seal (3) evenly to

press fit the rear seal.
3.
After press fitting rear seal (3), remove guide

(7).
a When removing the guide, take care not to
damage the seal lip.

removal.
Selection of seal
a When installing the rear seal, check the wear
of the crankshaft and select the standard seal
or "sleeved seal".
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 m) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a Left one in the following figure is the standard
seal and right one is the sleeved seal.
Procedure for installing standard seal

a Clean, degrease, and dry the contact face
against the flywheel housing.
a Check that the end corners of the crankshaft,
lip sliding surfaces, and housing are free from
flaws, burrs, rust, etc.
a Do not apply oil or grease to the crankshaft
and seal lip surface (a). Wipe off the oil from
the crankshaft.
a Never remove guide (7) installed to spare standard rear seal (3) before installing the rear
seal.
16
PC400, 450-7E0
4.
Install tool A6 and tighten 3 bolts (A6-1) evenly

until they stop to press fit rear seal (3).
a When press fitting the rear seal, take care
not to damage the seal lip with the tool,
etc.
5.
Remove 3 bolts (A6-1), fit 1 washer (A6-2)

press fit rear seal (3) until the end of tool A6
reaches the end of crankshaft (6).
a Press fitting distance (c) of rear seal from
crankshaft end: 16.3 mm
a When press fitting the rear seal, take care
not to damage the seal lip with the tool,
etc.
a After press fitting the rear seal, remove
the red sealant layer from its periphery.
SEN03609-01
Procedure for installing sleeved seal

a Clean, degrease, and dry the contact face
against the flywheel housing.
a Check that the end corners of the crankshaft,
lip sliding surfaces, and housing are free from
flaws, burrs, rust, etc.
a Do not apply oil or grease to the crankshaft
and the space between the inside cylinder of
sleeve (4) and seal lip (a). Wipe off the oil from
the crankshaft.
a Handle the rear seal and sleeve as an assembly and never separate them.
1.
PC400, 450-7E0
Set sleeve and seal assembly (3) to tool A7.

2 Sleeve inside cylinder surface:
Gasket sealant (LG-7)
17
SEN03609-01
2.
Apply sleeve (4) to sleeve and seal assembly

(3) to the end of crankshaft (6) and tighten 3
bolts (A7-1) of tool A7 evenly to press fit
sleeve and seal assembly (3).
a Fit 1 washer (A7-2) each to bolts (A7-1),
and tighten them until they stop.
3.
Replace tool A7 with tool A8 and tighten 3

bolts (A8-1) until they stop to press fit sleeve
and seal assembly (3).
4.
Remove 3 bolts (A8-1), fit 3 washers (A8-2)

press fit sleeve and seal assembly (3) until the
end of tool A8 reaches the end of crankshaft
(6).
a Press fitting distance (d) of sleeve and seal
assembly from crankshaft end: 16.3 mm
a After press fitting the seal, remove the red
sealant layer from its periphery.
18
PC400, 450-7E0
SEN03609-01

cylinder head assembly
6.
Remove clamp (4) and remove air intake tube

(5).
[*1]
7.
Remove the clamp and disconnect hose (9)

between the radiator and the engine at the
radiator side.
[*2]
8.
Remove covers (6), (7), and fan guard (8).
9.
Remove the exhaust pipe cover (10) and the

muffler cover (11).
A10 795-125-1360
Wrench
q 1
Filler gauge
q 1
Sketch
790-331-1110
N/R
A9
Part name
Qty
Part number
Necessity
Symbol
Special tools
Removal
1.
Drain coolant.
6
2.
Drain hydraulic oil.

6
3.
4.
Disconnect connector (P24) and overflow tube

(1) and remove the sub-tank (2).
5.

4
Engine hood: 200 kg
PC400, 450-7E0
19
SEN03609-01
10. Remove clamp (12) and two clamps (13) of

muffler. Shift the muffler (14) to remove the
joint tube (15) and the muffler (14).
11. Remove oil filter (10). (Leave the tube unremoved)
15. Disconnect the terminal of intake air heater

harness (19).
a Disconnect the clamp, too.
17. Disconnect the connectors EGR (21), SEGR

(22), TIM boost temperature sensor (23), wiring clamp (24), PIM boost pressure sensor
(25), PAMB atmospheric sensor (26) and connector (27).
a Remove clamps.
a Place removed parts together under the
engine.
[*4]
12. Remove the fuel pre-filter (16).

(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
13. Remove priming pump (17).
(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
14. Remove the fuel main filter (18).
(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine.) [*3]
20
PC400, 450-7E0
18. Remove clamp (28), bolt (29) and brackets

(30) to remove the housing complex (diffuser)
(31).
19. Remove brackets (behind the front hanger)
(32).
SEN03609-01
21. Remove clamp (34) and boots (35) to remove

6 high-pressure injection tubes (36). [*4] [*8]
20. Disconnect injector harness (33) and move it

to the lower left-hand side of the engine.
22. Remove the housing (41) by removing two

mounting bolts (38) from the side of air intake
manifold, two mounting bolts (39) from the side
of EGR valve and two mounting bolts (40) from
above.
[*5]
a
Disconnect fuel injector connector (c) with a

single action by inserting a flat-head screwdriver [1] to the stepped portion (a), then moving the driver in the direction of (X) while
pressing stopper of (b).
PC400, 450-7E0
21
SEN03609-01
25. Remove cover (44).
23. Sling the air intake manifold assembly (42),

remove 24 mounting bolts to remove the
assembly.
4
26. Remove tubes (45) (for taking out EGR exhaust

gas).
Air intake manifold: 25 kg
27. Remove EGR valve inlet tube cover (46).

24. Remove hose (43).
22
PC400, 450-7E0
28. Remove exhaust manifold heat insulation covers

(47).
29. Disconnect turbocharger lubrication inlet tube

(48) and disconnect the drain tube (49).
[*6]
30. Sling the turbocharger and exhaust manifold

assembly (50), and remove the mounting bolts.
[*7]
31. Remove turbocharger and exhaust manifold
assembly by hoisting.
4
SEN03609-01
32. Remove spill tube (51).
[*9]
33. Remove air vent tube (52).
[*10]
34. Remove head cover (53).
[*11]
35. Removal of injector harness

[*12]
1) Fully loosen two capture nuts (55) on the
head of injector (54).
a Loosen nuts alternately.
2) Loosen bolt (56) of harness fixing holder.
Turbocharger and exhaust manifold

assembly: 40 kg
PC400, 450-7E0
23
SEN03609-01
36. Removal of rocker arm assembly (57)

[*13]
1) Loosen locknut (58) and then loosen
adjustment screw (59).
2) Remove mounting bolt (60) and then
rocker arm and shaft assembly (57).
39. Remove 12 crossheads (65).
[*15]
40. Removal of injector harness connector

1) Remove mounting bolt (67) of harness
connector (66).
2) Remove holder (69) from the harness.
37. Remove 12 push rods (61).
3)
38. Remove holder mounting bolt (63) of injector
(62) and then remove injector along with
holder (64).
[*14]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
24
4)
Remove harness connector (70) by pushing it outward from inside of rocker housing (71).
Remove O-ring (72) from the rocker housing.
PC400, 450-7E0
41. Remove rocker housing (71).
SEN03609-01
[*16]
Installation
q

removal.
[*1]
Hose clamp: 9.8 0.5 Nm {100 5 kgcm}
[*2]
Radiator-related hose clamp:

3.3 0.49 Nm {0.3 0.05 kgm}
[*3]
42. Removal of cylinder head assembly

[*17]
1) Remove each set of 7 mounting bolts (74)
of cylinder head assembly (73).
2) Using eyebolt [1], lift and remove cylinder
head assembly (73).
4
3)
Cylinder head assembly: 20 kg
Remove each head gasket.
Fuel filter joint bolt:

24.5 34.5 Nm {2.5 3.5 kgm}
[*4]
Keep the harness assembly and other harnesses
10 mm and above away from the high-pressure
tube.
[*5]
Tighten the air intake manifold assembly mounting
bolts in the order given below.
3 Intake manifold assembly:
59 74 Nm {6 7.5 kgm}
[*6]
Lubrication tube sleeve nut:

40 44 Nm {4.1 4.5 kgm}
[*7]
Tighten the exhaust manifold assembly mounting
bolts in the order given below, then tighten other
bolts.
3 Exhaust manifold assembly mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
4
PC400, 450-7E0
Exhaust manifold assembly: 38 kg
25
SEN03609-01
[*8]
a For details on and how to install the high-press u r e tu b e c o v e r, s ee P a r a gr a p h [ * 5 ] i n
"Removal and installation of fuel injector
assembly."
High-pressure tube installation instructions
a Don't correct high-pressure tube by bending it
for re-use.
1) Tighten high-pressure tube permanently.
3 Sleeve nut:
39.2 49 Nm {4 5 kgm}
2) Temporarily tighten high-pressure clamp and
brackets all by hand.
3) Tighten high-pressure tube clamp permanently.
3 Clamp nut:
11.8 14.7 Nm {1.2 1.5 kgm}
4) Tighten bracket permanently.
5) Install cover.
a Direct the slit to the side of cylinder head.
6) Temporarily install gate-type bracket and cover
(also working as clamp).
7) Tighten the cover permanently.
3 Cover mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
8) Tighten the gate-type bracket permanently.
[*13]
1) Loosen locknut, then install rocker arm and
rocker shaft assembly.
3 Rocker shaft mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
2) Remove the cover and adjust the valve clearance.
Pointer is located under the cover.
q
Valve clearance
Intake : 0.33 mm
Exhaust : 0.71 mm
a See the paragraph of Adjusting valve clearance in the part for Testing and adjusting for
the valve clearance instructions.
3 Rocker arm locknut:
58.8 73.5 Nm {6 7.5 kgm}
[*14]
For the mounting instructions of injector and holder,
see the paragraph for the "Removal and installation
of fuel injector assembly."
[*15]
a Amply apply engine oil (EO30-CD) to crosshead guide and crosshead top face.
a Adjust the crosshead according to the following procedure.
1) Loosen the locknut and return the adjustment screw.
2) Holding the top of the crosshead lightly,
tighten the adjustment screw while keeping the crosshead in contact with the valve
stem.
3) After the adjustment screw touches the
valve stem, tighten it further by 20.
4) Tighten the locknut at this position.
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
[*16]
Rocker housing mounting bolt:

58.8 73.5 Nm {6 7.5 kgm}
[*9]
Spill tube: 9.8 12.7 Nm {1.0 1.3 kgm}
[*10]
Air vent tube: 9.8 12.7 Nm {1.0 1.3 kgm}
[*11]
Head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
[*12]
26
Capture nut: 2.0 2.4 Nm {0.2 0.24 kgm}
PC400, 450-7E0
[*17]
a Clean the bottom face, block top face and liner
with dry cloth or soaked with a solvent.
a Replace a bolt having 5 punch marks to the
bolt head.
a Tighten the bolt with hand and screw in to the
block by turning the bolt at least 2 rounds.
2 Bolt threaded portion and under side of
the bolt head:
LM-P or engine oil (EO30-CD)
a Tighten the cylinder head mounting bolts in the
order indicated in the figure.
3 Cylinder head mounting bolt 1 6:
1st time: 98.1 9.8 Nm {10 1 kgm}
2nd time: 166.6 176.4 Nm {17 18
kgm}
3rd time: Tighten bolt to 90 to 120
(target 120) using tool A9.
SEN03609-01
a
a
a
When not using tool A9

After applying a paint marking to the cylinder
head and bolt, tighten the bolt by 90 to 120
(target 120).
After tightening bolts 1 6, tighten auxiliary
bolt 7.
3 Cylinder head mounting auxiliary bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
After tightening the bolt, punch a mark on its
head.
When using a new bolt, do not punch a mark
on its head.
Feed coolant
coolant level.
5
PC400, 450-7E0
27
SEN03609-01

radiator assembly
2.
4.
6.
Remove radiator front cover (10).
7.
8.
9.
Remove undercover.
Remove cover (11).
Disconnect the lower hose (12).
Remove covers (1) and (2).
Drain coolant.
6
3.
Remove the clamp and hoses (6), (7), (8) and

(9) between the radiator and the engine. [*1]
Removal
1.
5.

4
Engine hood: 200 kg
10. Remove 2 upper mounting bolts (13).
28
PC400, 450-7E0
11. Lift and remove radiator assembly (14).

4
Radiator assembly: 30 kg
SEN03609-01
Installation
q

removal.
Feed coolant
coolant level again.
5
[*1]
PC400, 450-7E0
Radiator-related hose clamp

(8) : 3.3 0.49 Nm {0.3 0.05 kgm}
(7) : 4.4 0.49 Nm {0.45 0.05 kgm}
(6) : 8.8 0.49 Nm {0.9 0.05 kgm}
29
SEN03609-01

hydraulic oil cooler assembly
Removal
k
1.
2.
Completely ground the work equipment.

Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
Remove cover (1).
4.
6.
Remove tube (8).

Remove drain plug (7) and then remove fuel
tube (8) after draining oil inside.
Open the hydraulic oil tank cap before

draining to release the tank inner pressure. Then drain oil from the cooler hose.

4
30
Remove covers (5) and (6).
Remove cover under the hydraulic oil tank

drain plug. Remove the hydraulic oil tank drain
hose plug to drain hydraulic oil.
6
3.
5.
Engine hood: 200 kg
PC400, 450-7E0
7.
8.
9.
Remove 3 hydraulic oil cooler left-side mounting bolts (9) and remove a hydraulic oil cooler
front mounting bolt (10).
Remove 4 butterfly screws (11) from the
screen.
Disconnect upper piping (12).
SEN03609-01
Installation
q

removal.
Oil fill (hydraulic oil tank)

Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circulate the piping. Check the coolant level again.
10. Remove net on the hydraulic oil cooler side.

11. Hoist to remove hydraulic oil cooler assembly.
4
Hydraulic oil cooler assembly: 45 kg
PC400, 450-7E0
31
SEN03609-01

aftercooler assembly
9.
Removal
1.
2.
Open the radiator front cover.

Remove undercover (1).
Extract hoses (9) and (10) from the cooler

while pushing down the aftercooler assembly
(8).
[*1]
10. Hoist the cooler assembly with nylong slings,
etc. before the hose is completely extracted.
Withdraw the hose and pull out the aftercooler
assembly sideway to remove.
4
3.
Aftercooler assembly: 25 kg
Remove cover (2) under the aftercooler.
Installation
q

removal.
[*1]
Tightening torque procedure
1) Adjust the bridge position so that it will come
under the bridge band as shown in the figure
below.
2) Tighten till dimension (a) being 8 to 10 mm.
3) Tighten with a torque of 16 17 Nm (1.6 1.7
kgm).
4.
5.
6.
7.
8.
Remove evaporator (3) with the bracket as a

unit.
Remove plate (4).
Remove grease gun holder (5).
Loosen hose clamp (6).
Remove mounting bolt (7).
a:
b:
c:
d:
a
32
Dimension
Lapped portion of bridge and band
Bridge
Punch hole
Apply lubricant (Three-Bond band 18B) to the
threaded portion and tighten the bolt.
PC400, 450-7E0
SEN03609-01

engine and hydraulic oil pump
assembly
B
C
796T-601-1110 Stopper
4.

5.

4
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
3.
Engine hood: 200 kg
t 1 N Q
1 796-460-1210
Oil stopper
q 1
2 796-770-1320
Adapter
q 1
Removal
k
k
a
1.

Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
Take care not to mistake installation position of
each piping by attaching tags, etc.
Drain coolant.
6
2.
Remove hydraulic oil tank strainer and stop oil

using tool C.
a When not using tool C, remove the drain
plug and drain oil from hydraulic oil tank
and the piping.
6
6.
PC400, 450-7E0
Remove floor cover (4) on the control valve.

a Remove cover (4) to remove the following
covers (5) through (8).
33
SEN03609-01
7.
Remove covers (5), (6), (7) and (8).

a After removal, place the floor cover to
original position and temporarily tighten
the bolt.
10. Disconnect hose (15) under the radiator.
11. Disconnect hoses (16), (17) and (18) on the

radiator and overflow hose (19).
[*1]
8.
Open the cover beside the pump and remove

covers (9), (10) and (11) on the pump side and
the floor cover (12) on the pump.
a Remove in the order of (9) to (12).
12. Remove two sound absorbing cover (20), 2

covers (21) and fan guard (22).
9.
34
Remove undercovers (13) and (14).
PC400, 450-7E0
13. Remove fan (23).
SEN03609-01
17. Remove the terminal of intake air heater harness (29) and clamps (30).
14. Remove air intake tube (24) along with the

hose as a unit.
[*2]
19. Remove fuel hose (pump tank) (32), (33) and
fuel supply hose (tank block) (34).
15. Loosen adjustment nut (25) and locknut (26)

and remove V-belt from the pulley.
[*3]
16. Disconnect harness connector (M34), remove
the bracket mounting bolts, remove air conditioner compressor (28) and deposit them on
the floor cover.
PC400, 450-7E0
35
SEN03609-01
20. Remove engine controller cover (35).
21. Disconnect engine controller connectors CE02

(36) and CE03 (37).
[*4]
22. Remove harness clamp (38) at two locations.

23. Remove grounding T11 (39).
24. Disconnect oil level sensor connectors (40)
and (P44).
36
25. Disconnect return hose (41) and the clamp.

a Attach fuel stopper plug to the hose.
26. Disconnect the turbocharger hose (42).
27. Disconnect the car heater hose (43).
PC400, 450-7E0
28. Disconnect alternator wiring B (44), R (45) and

E (46).
29. Disconnect the car heater hose (47).
30. Remove harness clamps (48) at 3 locations

and grounding T12 (49).
31. Disconnect starter terminal B (50) and M7 connector.
PC400, 450-7E0
SEN03609-01
32. Remove grounding harness (51) (between

engine and frame).
33. Remove hydraulic pump piping.

q
(52) EPC source pressure port hose
(Collar band: Yellow)
q
(53) Rear pressure port hose
(Collar band: Yellow)
q
(54) Rear pump discharge port hose
q
(55) Front pump discharge port hose
q
(56) Drain port hose
q
(57) Front negative pressure input port hose
q
(58) Rear negative pressure input port hose
(Collar band: Red)
q
(59) Front pressure input port hose
q
(60) Pump suction port tube
34. Disconnect pump wiring connector at two locations.
q
(61) V22 (PC-EPC solenoid valve)
(Collar band: Red)
q
(62) V21 (LS-EPC Solenoid valve)
(Collar band: White)
37
SEN03609-01
36. Hoist to remove engine assembly (64).

a Remove after checking that wiring, piping
clamps, etc. are disconnected without
omission.
4
Engine, hydraulic pump assembly:

1,700 kg
35. Using tool B, remove 4 engine mount bolts

(63) in front and rear.
[*5]
a Easier to remove if nuts are heated by
gas.
38
PC400, 450-7E0
SEN03609-01
Installation
q

removal.
[*1]
Hose clamp:
(18) 3.3 0.49 Nm {0.3 0.05 kgm}
(17) 4.4 0.49 Nm {0.45 0.05 kgm}
(16) 8.8 0.49 Nm {0.9 0.05 kgm}
[*2]
Hose clamp:
9.8 0.5 Nm {100 5 kgcm}
[*3]
a See the paragraph for the Checking and
adjusting air conditioner compressor belt tension in Testing and adjusting or the paragraph
for the "Removal and installation of engine
front seal".
[*4]
Connector screw:
2.82 0.28 Nm {0.288 0.035 kgm}
[*5]
Engine mount bolt:

824 1030 Nm {84 105 kgm}
Feed coolant
coolant level again.
5
Oil feed (hydraulic oil tank)

Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circulate the piping. Check the oil level again.
5
Air bleeding
Refer to the paragraph on the "Bleeding air
from various parts" in Testing and adjusting.
PC400, 450-7E0
39
SEN03609-01

2008 KOMATSU
All Rights Reserved
40
SEN03610-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Power train
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 3
Removal and installation of swing motor and swing machinery assembly ....................................................11
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 12
Removal and installation of swing circle assembly ....................................................................................... 19
PC400, 450-7E0
SEN03610-01
Removal and installation of final

drive assembly
1
4.
Removal
1.
2.
Remove the sprocket. For details, see

Removal and installation of sprocket.
k Lower the work equipment to the
ground and stop the engine. Then,
loo sen the hyd raulic o il filler cap
slowly to release the internal pressure
of the hydraulic tank.
Remove the 24 mounting bolts and lift off the

final drive assembly (6).
[*1]
a Take care extremely not to damage the
nipple sealing faces of the hose joints.
a When slinging the final drive assembly, do
not use the tap hole for the cover.
4
Final drive assembly: 700 kg
Remove cover (1).
Installation
q
3.
Disconnect drain hose (2), travel speed selector hose (3), and motor hoses (4) and (5).
a Remove the nipples, too.
[*1]

removal.
3
Mounting bolt:
490 608 Nm {50 62 kgm}
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
Bleeding air
See Testing and adjusting, Bleeding air from
various parts.
PC400, 450-7E0
SEN03610-01
Disassembly and assembly of

final drive assembly
2)
Using eyebolt [2], remove cover (1).
796-627-1210
1
796-427-1140 Pin
01314-20612 Screw
796T-627-1230 Push tool
t 1
790-101-2510
Block
q 1
791-122-1130
Plate
q 1
Leg
q 2
Adapter
q 2
790-101-2570
Plate
q 4
790-101-2560
Nut
q 2
790-101-2102
Puller (30 tons)
t 1
790-101-1102
Pump
t 1
Installer
t 1
790-101-2550
3 796-627-1020
Sketch
Wrench assembly t 1
796-627-1220 Wrench
2 790-101-2740
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
3.
Spacer
Remove spacer (2).
4.
No. 1 carrier assembly

1) Remove No. 1 carrier assembly (3).
Disassembly
1.
Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6
2.
Final drive case: Approx. 11 l
Cover
1) Place the final drive on block [1] and
remove the mounting bolts.
PC400, 450-7E0
SEN03610-01
2)
Disassemble the No. 1 carrier assembly

i) Push in pin (5) to drive out shaft (6)
from carrier (7).
a After removing the shaft, remove
pin (5).
ii) Remove thrust washer (8), gear (9),
bearing (10), and thrust washer (11).
7.

1) Sling No. 2 carrier assembly (15) with
wires, etc. and remove it.
2)
5.
Sun gear
Remove spacer (4), No. 1 sun gear (12), and
No. 2 sun gear (13).
6.
Thrust washer
Remove thrust washer (14).
8.
Disassemble No. 2 carrier assembly

i) Push in pin (16) to drive out shaft (17)
from carrier (18).
a After removing the shaft, remove
pin (16).
ii) Remove thrust washer (19), gear
(20), bearing (21), and thrust washer
(22).
Nut
1) Remove lock plate (23).
PC400, 450-7E0
2)
9.
SEN03610-01
Using tool E1, remove nut (24).
Hub assembly
1) Using eyebolts [3], remove hub assembly
(25) from the travel motor.
2)
Disassemble hub assembly (25) according to the following procedure.

i) Remove bearing (26) from hub (32).
PC400, 450-7E0
3)
ii)
Remove floating seal (27) from hub

(32).
iii)
Remove bearings (28) and (29) from

hub (32).
Remove floating seal (30) from travel

motor (31).
SEN03610-01
4)
Using puller [4], remove bearing (34) and

collar (33) together.
a You can remove bearing (34) and collar (33) without using puller [4] in
some cases.
3)
Install collar (33) and bearing (34) to travel

motor (31).
4)
Using tool E3, install floating seal (30)

(which is hidden and not seen behind tool
E3) to travel motor (31).
a Thoroughly degrease and dry the Oring and O-ring fitting surface of the
floating seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding surfaces.
Assembly
a
Clean the all parts and check them for dirt or

damage. Coat their sliding surfaces with
engine oil before installing.
1.
Hub assembly
1) Using the push tool, press fit bearings (28)
and (29) to hub (32).
2)
Using tool E3, install floating seal (27) to

hub (32).
a Thoroughly degrease and dry the Oring and O-ring fitting surface of the
floating seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding surfaces.
PC400, 450-7E0
5)
2.
Using eyebolts [3], set hub assembly (25)

to the travel motor. Using the push tool,
lightly hit the bearing to press fit it.
Nut
Install the nut according to the following procedure.
1) Rotate the hub 2 3 turns.
2) Using tool E2, press the bearing inner race.
a Pressing force: 29.4 38.3 kN {3.0
3.9 tons}
3) While the bearing is pressed, rotate the
hub at least 5 turns in 1 direction.
4) Release the pressing force.
5) Press the bearing again.
a Pressing force: 14.7 18.6 kN {1.5
1.9 tons}
SEN03610-01
6)
Under the condition in 5) above, measure

dimension (a).
7)
8)
9)
Measure thickness (b) of nut (24).

Obtain (a) (b) = (c).
Using tool D1, tighten nut (24) until dimension (c) is as follows.
a Dimension (c): c +0.07
0.03 mm
10) Using push-pull gauge [5], measure the

tangential force of the hub in its revolving
direction on the motor case.
a Tangential force: Max. 765 N {78 kg}
a The tangential force means the maximum force at the beginning of rotation.
PC400, 450-7E0
SEN03610-01

a
11) Install lock plate (23), fitting it to the motor

spline.
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
2)
3.

1) Assemble the No. 2 carrier assembly
a There is a caulking mark made when
the pin was inserted at the end of carrier side hole (h) and the inside wall of
the hole is swelled at that mark. Flatten the swelled part in advance.
i) Install bearing (21) to gear (20) and fit
top and bottom thrust washers (19)
and (22) , and then set the gear
assembly to carrier (18).
4.
ii)
iii)
After assembling the carrier assembly, check that the gear (20) turns
smoothly.
Install No. 2 carrier assembly (15).

a Install No. 2 carrier assembly (15) so
that the 4 gear shaft ends will be in
the 4 hollows at the motor case end.
Thrust washer
Install thrust washer (14).
Aligning the pin holes of shaft (17)

and carrier, lightly hit the shaft with a
plastic hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care
not to damage the thrust washers.
Insert pin (16).
a After inserting the pin, caulk the
pin part of the carrier.
PC400, 450-7E0
5.
SEN03610-01
ii)
No. 2 sun gear

Install spacer (4) and No. 2 sun gear (13).
iii)
a
6.

the pin was inserted at the end of carrier side hole (h) and the inside wall of
i) Install bearing (10) to gear (9) and fit
a nd (11 ), and the n s et the gear
PC400, 450-7E0
2)
Aligning the pin holes of shaft (6) and

carrier, lightly hit the shaft with a plastic hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care
not to damage the thrust washers.
Insert pin (5).
a After inserting the pin, caulk the
pin part of the carrier.
After assembling the carrier assembly, check that the gear (9) turns
smoothly.
SEN03610-01
7.
No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).
8.
Spacer
Install spacer (2).
9.
Cover
Using eyebolts [2], install cover (1) and tighten
the mounting bolts.
2
3
10
After installing spacer (2), measure distance (j) from the top of planetary gear (9)
to the top of hub assembly (25) and check
the assembly condition.
q
Dimension (j): 1.2 mm
If dimension (j) is less than 1.2 mm or the
top of planetary gear (9) is projected from
the top of hub assembly (25), they are not
assembled correctly. In this case, check
again.
Cover mounting face:

Mounting bolt:
98 123 Nm {10 12.5 kgm}
Refilling with oil

a Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely
cold district) through the oil filler.
5
Final drive case: Approx. 11 l
After installing the final drive assembly to

the chassis, check the oil level again at
the specified position.
PC400, 450-7E0
Removal and installation of swing

motor and swing machinery
assembly
1
SEN03610-01
3.
Removal
k
1.
Release the residual pressure in the

hydraulic circuit. Refer to the Releasing
residual pressure from hydraulic circuit
section in the Testing and adjusting chapter of this manual.
for oil filler cap on the fuel tank to release
the residual pressure inside the tank and
move the work equipment lock lever to the
LOCK position.
Disconnect five swing motor hoses (1) through
(5).
q
(1): Between swing motor and control
valve (MA port)
q
(2): Between swing motor and control
valve (MB port)
q
(3): Suction hose (S port)
q
(4): Drain hose (T port)
q
(5): Swing brake releasing pilot hose (B
port)
[*1]
Disconnect the swing motor and swing

machinery assembly (6), using forcing screw
[1] after removing the mounting bolts.
[*1]
PC400, 450-7E0
Swing motor and swing machinery

assembly: 550 kg
Installation
q
2.
Lift and remove swing motor and swing

machinery assembly (6).
a When lifting the swing motor and swing
machinery assembly for removal, do so
slowly so that the hoses and other parts
will not be damaged.
a Take good care, when lifting the assembly,
until the spigot joint portion is pulled out.
Install in reverse order of removal.

3
Mounting bolt:
824 1,030 Nm {84 105 kgm}
Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
Air bleeding
Refer to the Bleeding air from various parts in
the Testing and adjusting chapter of this manual.
11
SEN03610-01

swing motor and swing
machinery assembly
3.
No. 1 sun gear

Remove No. 1 sun gear (2).
4.

1) Remove No. 1 carrier assembly (3).
1 796T-627-1630 Push tool
q 1
2 790-201-2350
Push tool
t 1
3 790-201-2510
Push tool
t 1
Push tool kit
t 1
790-101-5401
D 4
790-101-5531 Plate
790-101-5421 Grip
01010-51240 Bolt
5 790-201-2870
Push tool
t 1
6 790-201-2770
Push tool
t 1
7 796T-626-1110 Push tool
t 1
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Disassembly
1.
Draining oil
Loosen the drain plug and drain the oil from
the swing machinery case.
6
2.
Swing machinery case: Approx. 21 l
Swing motor assembly

1) Set the swing motor and swing machinery
assembly on block [1].
2) Remove 10 mounting bolts and lift off
swing motor assembly (1).
4
12
Swing motor assembly: 115 kg
2)

Remove snap ring (4), and then remove
shaft (5), gear (6), bearing (7), thrust
washer (8), and plate (9).
PC400, 450-7E0
5.
Ring gear
Remove the mounting bolts and ring gear (10).
6.
No. 2 sun gear

Remove No. 2 sun gear (11).
7.
Bolt
Remove holder mounting bolt (12).
SEN03610-01
8.
2)
9.
PC400, 450-7E0

1) Lift of No. 2 carrier assembly (13).

i) Push in pin (14) and drive out shaft
(15) from carrier (16).
a After removing the shaft, remove pin
(14).
ii) Remove thrust washer (17), gear
(18), bearing (19), and thrust washer
(20).
iii) Remove plate (21).
Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of
cover assembly (22).
13
SEN03610-01
2)
Turn over case and pinion assembly (24)

and set it on the press stand. Using push
tool [2], D1 and the press, pull out pinion
shaft assembly (25).
a Set a wood block under the press so
that the pinion shaft will not be damaged when it comes off.
a A rough standard pressing force is 20
odd tons.
11. Bearing
Using multiple push tools [3], remove bearing
(30) from case (31).
a Push tool to be set contact with bearing:
D2
Assembly
10. Disassemble the pinion shaft assembly (25)
1) Using the push tool, remove cover assembly (22) and bearing (26) from shaft (27).
tons.
2) Remove oil seal (28) from cover (29).
14
Clean the all parts and check them for dirt or

damage. Coat their sliding surfaces with
engine oil before installing.
1.
Bearing
Using push tool D3 and [4], press fit bearing
(26) to case (31).
a A rough standard pressing force is several
tons.
PC400, 450-7E0
2.
Cover assembly
1) Using push tool D4, press fit oil seal (28)
to cover (29).
2 Periphery of oil seal:
a Take care that the gasket sealant
(LG-6) will not stick to the oil seal lip
and shaft.
2)
Install cover assembly (22) to case (31)

and tighten mounting bolts (23).
a Match the oil path of cover (22) to the
drilled hole of case (31).
2 Cover fitting face:
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
2 Oil seal lip: Grease (G2-LI)
PC400, 450-7E0
SEN03610-01
3.
Case assembly
1) Turn over case assembly (32) and set it to
shaft (27). Using push tools D5 and D6 [5],
press fit the bearing inner race.
a When setting the case assembly to
the shaft, take care extremely not to
damage the oil seal.
tons.
2)
Bearing
Using too D7, press fit bearing (30).
a Press both inner race and outer race
of the bearing simultaneously. Do not
press only the inner race.
odd tons.
a After press fitting the bearing, check
that the case turns smoothly.
15
SEN03610-01
4.

a

the pin was inserted at the end of carrier side hole (a) and the inside wall of
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit
and (20) , and then set the gear
When inserting the pin, do not set the

3 claws (a) on the periphery to the
thin part of the carrier (b).
The thin part may be on the opposite
side, however. Check each carrier
and avoid setting a claw to the thin
part.
2)
5.
iii)
Aligning the pin holes of shaft (15)

and carrier, lightly hit the shaft with a
plastic hammer, etc. to install.
a When installing the shaft, revolve the
planetary gear and take care not to
damage the thrust washers.
iv) Insert pin (14).
Bolt and O-ring

1) Tighten bolt (12).
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
343 427 Nm {34 43.5 kgm}
2)
16
After inserting the pin, caulk the pin

part of the carrier.
Fit the O-ring to case (31).
PC400, 450-7E0
6.
SEN03610-01
No. 2 sun gear

Install No. 2 sun gear (11).
a
7.
Ring gear
Using the eyebolt (M12 x 1.75), install ring
gear (10).
a
8.
Degrease the mating faces of ring gear

(10) and case (29).
Never stick gasket sealant to the mating
faces of ring gear (10) and case (29).
3 Mounting bolt:
245 309 Nm {25 31.5 kgm}
Add engine oil (EO30-CD) at this time.

i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap
ring groove is seen.
ii) After installing snap ring (4), press
back the shaft from the opposite side
until the snap ring is fitted to face (P)
of the carrier. At this time, take care
not to press back too much.
When installing ring gear (10), set its

match mark (d) and the projection of the
case flange (c) as shown in the following
figure.
PC400, 450-7E0
17
SEN03610-01
iii)
2)

a
After installing plate (9), install thrust

washer (8), bearing (7), gear (6), and
snap ring (4).
Take care not to install the No. 1 sun gear

upside down.
Install the No. 1 sun gear with the tooth (e)
down.

10. Swing motor assembly
Install swing motor assembly (1) to ring gear
(10).
a When installing the swing motor assembly,
set the relief valve (f) and the projection of
the case (c) as shown in the following figure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear (10).
2
9.
No. 1 sun gear assembly

Install No. 1 sun gear (2).
Refilling with oil

Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely cold
district) through the oil filler to the specified
level.
5
18
Mating faces of swing motor

assembly (1) and ring gear (10):
Mounting bolt:
98 123 Nm {10 12.5 kgm}
Swing motor assembly: 115 kg
Swing machinery case: Approx. 21 l
PC400, 450-7E0
SEN03610-01
Removal and installation of swing

circle assembly
1
Installation
Removal
[*1]
1.
Remove the revolving frame assembly. For

details, see Removal and installation of
revolving frame assembly.
2.
Sling swing circle assembly (1) by 3 points

temporarily, remove 40 mounting bolts, and lift
off the swing circle assembly.
[*1]
4
Swing circle assembly: 600 kg
PC400, 450-7E0

removal.
Mating face of swing circle:

2 Threads of swing circle mounting bolt:
Adhesive (LT-2)
3 Swing circle mounting bolt:
824 1,030 Nm {84 105 kgm}
Target: 927 Nm {94.5 kgm}
a When installing the swing circle to the
track frame, bring soft zone mark (S) of
the inner race and soft zone mark (P) of
the outer race to the right side of the chassis as shown below.
2 Quantity of grease in grease bath:
Grease (G2-LI), 33 l
(Use GLT2-LI for 50C specification)
19
SEN03610-01

2008 KOMATSU
All Rights Reserved
20
SEN03611-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Disassembly and assembly of carrier roller assembly .................................................................................... 2
Disassembly and assembly of track roller assembly ...................................................................................... 4
Disassembly and assembly of idler assembly ................................................................................................ 5
Disassembly and assembly of recoil spring assembly .................................................................................... 8
Removal and installation of sprocket ............................................................................................................ 10
Expansion and installation of track shoe assembly........................................................................................11
Removal and installation of revolving frame assembly ................................................................................. 13
Removal and installation of counterweight assembly ................................................................................... 16
PC400, 450-7E0
SEN03611-00

carrier roller assembly
a
Floating seal
a When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating
seal (hatched parts). Take care that dirt
will not stick to the floating seal contact
surfaces.
a Be sure to use the installer F to insert the
floating seal assembly in the housing.
a After installing the floating seal, check that
its slant is less than 1 mm and its projection (a) is 5 7 mm.
Carrier roller
a Using tool F, apply the standard pressure
to the oil filler to check the seal for air leakage.
a Keep the following standard pressure for
10 seconds and check that the pointer of
the gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
Only precautions for assembling the carrier

roller assembly are explained below.
1 791-430-3230
Installer
t 1
2 791-601-1000
pump
t 1
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Carrier roller assembly: 30 kg
Assembly
q
Press fitting of support (2)

1) Press fitting dimension of shaft: (Shown in
the following figure)
2) Using push tool [1], press fit support (2) to
shaft (1). At this time, apply press fitting
force of at least 21.6 24.5 kN {2.2 2.5
tons}.
PC400, 450-7E0

a
SEN03611-00
Using tool F, fill the carrier roller assembly

with oil and tighten the plug.
Carrier roller: 170 180 cc (EO30-CD)
PC400, 450-7E0
SEN03611-00

track roller assembly
a
Only precautions for assembling the track

roller assembly are explained below.
1 791-630-1780
Installer
t 1
2 791-601-1000
Oil pump
t 1
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Track roller
a Using tool G, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for
10 seconds and check that the pointer of
the gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
Track roller assembly: 75 kg (Single)

85 kg (Double)
Assembly
q
Floating seal
a When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating
surfaces.
a Be sure to use the installer G to insert the
a After installing the floating seal, check that
Using tool G, fill the track roller assembly

with oil and tighten the plug.
Track roller:
280 310 cc (Single) (EO30-CD)
280 290 cc (Double) (EO30-CD)
Plug: 10 20 Nm {1 2 kgm}
PC400, 450-7E0
SEN03611-00

idler assembly
4.
Remove floating seal (7) on the opposite side

from idler (5) and shaft and support assembly
(6).
5.
Remove nut (8), pull out bolt (9), and then

remove support (10) from shaft (11).
6.
Remove bushing (12) from idler (5).
791-575-1520
Installer
t 1
791-601-1000
Oil pump
t 1
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
Idler assembly: 230 kg
Disassembly
1.
Remove nut (1) and pull out bolt (2) to remove

support (3).
2.
Remove floating seal (4) from support (3) and

idler (5).
3.
Pull out idler (5) from shaft and support assembly (6).
a Idler is filled with oil of 345 10 cc. Drain it
or spread cloths to soak it at this time.
PC400, 450-7E0
SEN03611-00

a
Assembly
1.
Press fit bushings (12) (on both sides) to idler

(5).
2.
Fit the O-ring and install support (10) to shaft

(11) with bolt (9) and tighten nut (8).
a
a
3.
When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating
surfaces.
Be sure to use the installer H to insert the
After installing the floating seal, check that
Install the shaft with the UP mark up.
4.
Install shaft and support assembly (6) to idler

(5).
5.
Similarly, using too H, install floating seal (4) to

idler (5) and support (3).
Using tool H, install floating seal (7) to idler (5)

and shaft and support assembly (6).
PC400, 450-7E0

a
a
SEN03611-00
Coat the sliding surface of the floating seal

with oil and take care that dirt will not stick
to it.
Degrease the floating seal and the O-ring
contact surfaces.
6.
Fit the O-ring, set support (3), install bolt (2),

and tighten nut (1).
7.
Add oil and tighten the plug.

5
3
Quantity of oil:
Approx. 345 10 cc (EO-30CD)
Plug: 130 180 Nm {13 18 kgm}
PC400, 450-7E0
SEN03611-00

recoil spring assembly
791-685-8006
Compressor
t 1
791-635-3160
Extension
t 1
790-101-1600
Cylinder
(680 kN {70 t})
t 1
790-101-1102
Pump
t 1
790-201-1500
Push tool kit
790-201-1660 Plate
2.
Disassembly of recoil spring assembly

1) Set tool J1 to recoil spring assembly (1).
k Since the installed load of the spring is
large and dangerous, set t he tool
securely.
a Installed load of spring:
239.037 kN {24,375 kg}
N/R
Sketch
Qty
Necessity
Symbol
1
Part name
Remove piston assembly (2) from recoil spring

assembly (1).
Special tools
Part number
1.
1
1
790-101-5021 Grip
01010-50816 Bolt
Recoil spring (Excluding idler): 900 kg

2)
Disassembly
3)
3.
Apply oil pressure gradually to compress

the spring and remove lock plate (3) and
nut (4).
a Compress the spring to a degree that
you can loosen the nut.
a Release the oil pressure gradually to
reduce the spring tension to 0 (zero).
a Free length of spring: 845.3 mm
Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
Disassembly of piston assembly

1) Remove lock plate (11) from piston (10),
and then remove valve (12).
2) Remove snap ring (13), U-packing (14),
and ring (15).
PC400, 450-7E0
SEN03611-00
Assembly
1.
Assembly of piston assembly

1) Install ring (15) and U-packing (14) to piston (10) and secure them with snap ring
(13).
2) Tighten valve (12) temporarily and secure
it with lock plate (11).
2.
Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylinder (7).
3.
PC400, 450-7E0
2)
Install cylinder (7), collar (8), and yoke (6)

to spring (5), and then set them to tool J1.
2 Sliding parts of cylinder:
Grease (G2-LI)
3)
Apply oil pressure gradually to compress

the spring and tighten nut (4) so that
installed length of the spring will be (a),
and then secure it with lock plate (3).
a Installed length of spring (a):
Approx. 690 mm
4)
Remove recoil spring assembly (1) from

tool J1.
Install piston assembly (2) to recoil spring

assembly (1).
2 Sliding parts of piston: Grease (G2-LI)
2 Wear ring: Grease (G2-LI)
a Install the piston assembly so that the
position of the valve will be on outside.
a Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease
flows out of the grease hole.
SEN03611-00

sprocket
Installation
[*1]
Removal
1.
Remove track shoe assembly. For details, see

Removal and installation of track shoe assembly.
2.
Swing work equipment 90, push up chassis

with work equipment and place block [1]
between track frame and track shoe.
3.
Remove mounting bolts and lift off sprocket

(1).
[*1]
4
10
Install in reverse order of removal.

2
3
Thread of sprocket mounting bolt:

Sprocket mounting bolt:
640 785 Nm {65 80 kgm}
Sprocket: 70 kg
PC400, 450-7E0
SEN03611-00
Expansion and installation of

track shoe assembly
4.
Using tool K, remove master pin (1).
[*3]
5.
Move the master pin forward and set block [1]

under the track shoe in front of the idler.
6.
Pull out pusher K.
7.
Move the machine in reverse slowly to expand

the track shoe.
[*4]
1 791-650-3000
Remover and
installer
t 1
2 790-101-1300
Cylinder
(980 kN {100 t})
t 1
3 790-101-1102
Pump
t 1
Sketch
N/R
Part name
Qty
Part number
Necessity
Symbol
Special tools
Expansion of track shoe

1.
Start the engine and set the master pin to

above the idler.
2.
Remove track shoes (2) on the right and left

sides of master pin (1).
[*1]
3.
Lower the work equipment to the ground and

loosen lubricator (3) to slacken the track shoe.
[*2]
k Since the internal pressure of the
adjustment cylinder is very high, do
not loosen the lubricator more than 1
turn. If the grease does not come out
sufficiently, move the machine forward
and in reverse.
PC400, 450-7E0
11
SEN03611-00

2Apply
Installation of track shoe

q
[*1]

expansion.
2
[*2]
Tightening torque for lubricator:

58.8 88.3 Nm {6 9 kgm}
Using the tool, press fit the master pin so

that its projection (a) will be as follows.
q
Dimension (a): 4.4 2 mm
12
Mounting bolt: Anti-seizure compound

( M A R U Z E N M O LY M A X N o . 2 o r
equivalent)
Mounting bolt: Tighten the 4 bolts first to
392 39 Nm {40 4 kgm}. Check that
the mating faces are fitted, then
retighten each bolt by 120 10.
Adjust the tension of the track shoe. For

detail, see Testing and adjusting, Checking and adjusting track shoe tension.
[*3]
grease to the contact faces of dust

seal (5) and bushing (4) (all over the
end face of the dust seal or bushing)
(parts marked O). Do not apply grease
to the pars marked (X), however.
R: Detail of regular pin position
M: Detail of master pin position
(Pins are not inserted, however)
[*4]
Set the track shoe and sprocket (4) as shown
in the following figure (on both right and left
sides).
Supply grease to the space between the

bushing and pin so that filling rate will
be 100%.
Grease: NIGTITE LYK-2 manufactured
by NIPPON GREASE CO., LTD. or
equivalent
PC400, 450-7E0

revolving frame assembly
SEN03611-00
Removal
k
Extend the arm and bucket fully, lower the

work equipment to the ground, and set the
work equipment lock lever to the LOCK
position.
1.
Remove the work equipment assembly. For

details, see Removal and installation of work
equipment assembly.
2.
Remove the counterweight assembly. For

details, see Removal and installation of counterweight assembly.
3.
6.
Disconnect 4 boom cylinder hoses (1).

a Plug the hoses to stop oil.
7.
4.
Sling boom cylinder assembly (2) temporarily.
5.
Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
a Remove the boom cylinder on the opposite side similarly.
4
Disconnect 7 hoses (5) (11).

(5): Center swivel joint (Port D) Swing
motor (Port T)
q
(6): Center swivel joint (Port D) Hydraulic tank
q
(7): Center swivel joint (Port E) Solenoid valve
q
(8): Center swivel joint (Port B) Control
valve left travel (Port B2)
q
(9): Center swivel joint (Port D) Control
valve right travel (Port B5)
q
(10): Center swivel joint (Port A) Control
valve left travel (Port A2)
q
(11): Center swivel joint (Port C) Control
valve right travel (Port A5)
q
Pull out pin (12) on the center swivel joint side

and disconnect the lock plate from the center
swivel joint.
Boom cylinder assembly: 360 kg
PC400, 450-7E0
13
SEN03611-00
8.
Remove 29 mounting bolts (13), leaving 3

each at the front and rear sides.
Installation
q

removal.
[*1]
Match the soft zone point (P) of the outer race
and the soft zone point (S) of the inner race.
2 Mating face of swing circle:
2 Threads of revolving frame mounting bolt:
Adhesive (LT-2)
9.
Using a lever block, sling the revolving frame

assembly temporarily, balancing it in each
direction.
a Put wood liners to the rear side of the
frame.
q
Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
a If the engine hood interferes with the sling,
e r e c t th e e n gi n e h o o d , r ef e r r i n g t o
Removal and installation of radiator
assembly.
10. Remove the remaining 6 bolts and lift off

revolving frame assembly (14).
[*1]
k When removing the revolving frame
assembly, take care that it will not interfere with the center swivel joint assembly.
4
14
Revolving frame assembly: 10,000 kg
PC400, 450-7E0
SEN03611-00
1.
Revolving frame mounting bolt

Tighten the bolts marked with A (at 4 places)
according to the following steps 1) 3).
1) Tighten each bolt to 392 Nm {40 kgm} first.
2) Then, tighten the bolt by 90 5.
q
Make a mark on the bolt head with a
marker pen (to check the angle).
3) The tightening torque of the bolt tightened
in 2) above must be 1,176 Nm {120 kgm}
or larger.
2.
Tighten each bolt 208-25-71230 which is not

marked with A according to above steps 1)
3). If the tightening torque reaches 2,254 Nm
{230 kgm} before completing the above steps
and the tightening angle is 35 95, however,
stop tightening.
Marks (P) and (S) are the soft zone points.

again.
Bleeding air
Bleed air from the travel motor. For details, see
Testing and adjusting, Bleeding air from various parts.
PC400, 450-7E0
15
SEN03611-00

counterweight assembly
Installation
Removal
1.
Open engine inspection cover at the counterweight side.

a Because the handle of the cover touches
the counterweight.
2.
Set eyebolt [1] to counterweight assembly (1).
3.
Remove 4 mounting bolts (2).

removal.
a If heat insulation cover (3) of the engine
compartment is flattened, replace it.
[*1]
[*1]
2
3
4.
Lift off counterweight assembly (1).

[*2]
a Check where shims have been used.
a When lifting off the counterweight, take
care not to strike it against the engine,
radiator and cooler assembly, etc.
4
16
Counterweight assembly: 9,500 kg
Threads of mounting bolt: Adhesive (LT-2)

Mounting bolt:
3,430 4,212 Nm {350 430 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exterior parts (horizontal clearance) with
shims.
q
Kinds of shim thickness: 0.5 mm, 1 mm
2) Insert the shims so that the clearance
between the door and counterweight and
that between the revolving frame and
counterweight will be 10 5 mm evenly.
PC400, 450-7E0
PC400, 450-7E0
SEN03611-00
17
SEN03611-00

2008 KOMATSU
All Rights Reserved
18
SEN03612-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Hydraulic system
Removal and installation of center swivel joint assembly ............................................................................... 2
Disassembly and assembly of center swivel joint assembly........................................................................... 4
Removal and installation of hydraulic tank assembly...................................................................................... 5
Removal and installation of control valve assembly ....................................................................................... 7
Disassembly and assembly of control valve assembly ................................................................................. 10
Removal and installation of hydraulic pump assembly ................................................................................. 14
Removal and installation of oil seal in hydraulic pump input shaft ................................................................ 17
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 18
Disassembly and assembly of travel PPC valve assembly........................................................................... 20
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 22
PC400, 450-7E0
SEN03612-01
Removal and installation of center

swivel joint assembly
1
q
q
Removal
k
a
1.
Release the remaining pressure in the

hydraulic circuit. For details, see Testing
and adjusting, Releasing residual pressure from hydraulic circuit.
Mark all the piping with tags to prevent mistakes in the mounting position when installing.
Disconnect six hoses (1) through (6) between
travel motor and center swivel joint.
q
(1): Center swivel joint (T port) Left
travel motor (T port)
q
(2): Center swivel joint (T port) Right
travel motor (T port)
q
(3): Center swivel joint (B port) Left
travel motor (PA port)
q
(4): Center swivel joint (D port) Right
travel motor (PB port)
q
(5): Center swivel joint (A port) Left
travel motor (PB port)
q
(6): Center swivel joint (C port) Right
travel motor (PA port)
(14): Center swivel joint (A port) Left

travel control valve (A2 port)
(15): Center swivel joint (C port) Right
travel control valve (A5 port)
3.
Pull out pin (16) on the side of center swivel

joint and remove the jam plate from the center
swivel joint.
4.
Remove four mounting bolts (17).
5.
Remove center swivel joint assembly (18). [*1]

4
2.
Center swivel joint assembly: 40 kg
Disconnect nine hoses (7) through (15).

(7): Center swivel joint (E port) Left
travel motor (P port)
q
(8): Center swivel joint (E port) Right
travel motor (P port)
q
(9): Center swivel joint (D port) Swing
motor (T port)
q
(10): Center swivel joint (D port) Hydraulic tank
q
(11): Center swivel joint (E port) Solenoid valve
q
(12): Center swivel joint (B port) Left
travel control valve (B2 port)
q
(13): Center swivel joint (D port) Right
travel control valve (B5 port)
q
PC400, 450-7E0
SEN03612-01
Installation
q

removal.
[*1]
Install the center swivel joint facing in the direction shown in the diagram.
(The diagram shows the machine as seen from
above.)
Refilling with oil (hydraulic tank)

through the system. Then check the oil level
again.
Bleeding air
Bleed the air from the travel motor. For details,
see Testing and adjusting, Bleeding air from
various parts.
PC400, 450-7E0
SEN03612-01

center swivel joint assembly
790-101-2501
Push puller
q 1
790-101-2510 Block
790-101-2520 Screw
791-112-1180 Nut
790-101-2540 Washer
790-101-2630 Leg
790-101-2570 Plate
790-101-2560 Nut
790-101-2650 Adapter
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
1.
Remove cover (1).
2.
Remove snap ring (2).
3.
Using tool M, pull out swivel rotor (4) and ring

(3) from swivel shaft (5).
4.
Remove seal (6) from swivel shaft (5).
5.
Remove O-ring (7) and slipper seal (8) from

swivel rotor (4).
Disassembly
Assembly
1.
Assemble slipper seal (8) and O-ring (7) to

swivel rotor (4).
2.
Assemble seal (6) in swivel shaft (5).
3.
Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer
to install.
2 Contact surface of rotor, shaft:
Grease (G0-LI or G2-LI)
a When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.
4.
Install ring (3) and secure with snap ring (2).
5.
Install O-ring and cover (1).

3 Mounting bolt:
31.4 2.9 Nm {3.2 0.3 kgm}
PC400, 450-7E0

hydraulic tank assembly
SEN03612-01
6.
Disconnect block (7) together with return hose.
7.
Disconnect drain hoses (8), (9), and (10).
8.
Disconnect 2 clamps (11).
9.
Remove side cover (12).
Removal
1.
2.
Remove 3 lower covers (1).
Drain the oil from the hydraulic tank.

6
3.
Capacity of hydraulic tank:

Approx. 335 l
Remove control valve top cover (3).
10. Remove sensor (13).

11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily
and remove 6 mounting bolts (15).
[*1]
4.
Remove cover (4).
5.
Disconnect drain hoses (5) and (6).
PC400, 450-7E0
SEN03612-01
13. Lift off hydraulic tank assembly (16).

4
Hydraulic tank assembly: 200 kg
Installation
q

removal.
[*1]
Mounting bolt:
254.2 308.9 Nm {25.0 31.5 kgm}

again.
5

Approx. 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
Bleeding air
various parts.
PC400, 450-7E0

control valve assembly
SEN03612-01
q
q
(13): Port PP1 hose (Front pump)

(14): Port PP2 hose (Rear pump)
(15): Port T hose (Oil cooler)
Removal
k

and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank and
set the work equipment lock lever to the
LOCK position.
Put tags to the disconnected hoses and tubes
to prevent a mistake in re-connecting them.
1.
Open engine inspection cover (1).
2.
Remove control valve top cover (2).
3.
Remove partition covers (3), (4), and (5)

between the engine and control valve.
4.
Remove the control valve bottom cover.
5.
Disconnect the 2 wiring connectors and 8

hoses.
q
(6): A51 (Front pump pressure sensor)
q
(7): A52 (Rear pump pressure sensor)
q
(8): Port PS hose (Hose band: Yellow-Blue)
q
(9): Port PST hose (Hose band: Brown)
q
(10): Port PPS2 hose (Rear pump, red)
q
(11): Port PR hose (Solenoid)
q
(12): Port PR hose (Pump, yellow)
PC400, 450-7E0
6.
Disconnect the following 4 control valve hoses:

q
(16): Port PPS1 hose (Front pump)
q
(17): Port PLS2 hose (Hose band: Brown)
q
(18): Port PLS1 hose
q
(19): Port PX1 hose (Hose band: Blue)
7.
Remove relay bracket (20) and clamp (21).
8.
Disconnect drain hose (22). (To tank)
9.
Disconnect the following 6 left PPC hoses.

q
(23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm OUT (Hose band: Yellow)
SEN03612-01
10. Disconnect 4 boom hoses (24).

11. Remove boom tube clamps (25) and (26).
15. Disconnect the following 6 right PPC hoses.

q
(30): Bucket DUMP (Hose band: Black)
q
(31): Left travel FORWARD
(Hose band: Red)
q
(32): Boom LOWER (Hose band: Brown)
q
(33): Right SWING
q
(34): Right travel FORWARD
(Hose band: Green)
q
(35): Arm IN (Hose band: Blue)
12. Disconnect port TSW hose (27) (Swing motor

port S).
13. (28): In order from top
Remove port A-1 tube (Boom Hi bottom side).
Remove port A1 tube (Bucket bottom side).
Disconnect port A2 hose (Swivel joint port A).
After removing the hoses from ports B, remove
port A3 tube (Boom bottom side).
Remove port A4 hose (Swing motor port MB).
Disconnect port A5 hose (Swivel joint port C).
Remove port A6 tube (Arm head side).
16. Disconnect the following 3 control valve hoses.

a Do not disconnect hose C.
q
(36): Port BP5 hose (To solenoid)
q
(37): Port PX2 hose
q
(38): Port TS hose
14. (29): In order from top

Disconnect port B-1 hose (Arm Hi bottom side).
Disconnect port B1 hose (Bucket head side).
Disconnect port B2 hose (Swivel joint port B).
Remove port B3 tube (Boom head side).
Remove port B4 hose (Swing motor port MA).
Disconnect port B5 hose (Swivel joint port D).
Remove port B6 tube (Arm bottom side).
PC400, 450-7E0
17. Sling control valve assembly (40) temporarily

and remove 3 mounting bolts (39).
SEN03612-01
Installation
q

removal.

again.
Bleeding air
various parts.
18. Lift off control valve assembly (40).

4
Control valve assembly: 250 kg
PC400, 450-7E0
SEN03612-01

control valve assembly
a
Only precautions for assembling the pressure

compensation valve assembly and control
valve assembly are explained below.
Replacement procedure for pressure compensation valve seal

a Since there many types of the pressure compensation valves, make a mark on each valve
to indicate from where it was removed.
1.
Remove piston (2), plug (3), and spring (4)

from pressure compensation valve (1).
2.
Remove seal (5) and O-ring (6) from piston (2).
796-946-1310
Guide 21.8
(For 723-46-40100, 723-46-40601)

1
796-946-2110
Guide 20.9
(For 723-46-44100)
796-946-2210
Guide 20.6
(For 723-46-45100, 723-46-45500)

796-946-1320
Guide
(For 723-46-40100, 723-46-40601)

796-946-1420
2
L
Guide 21.6
(For 723-46-42800)
796-946-2120
Guide
(For 723-46-44100)
796-946-2220
Guide
(For 723-46-45100, 723-46-45500)

796-946-1330
Sleeve
(For 723-46-40100, 723-46-40601)

796-946-1430
3
Sleeve
(For 723-46-42800)
796-946-2130
Sleeve
(For 723-46-44100)
796-946-2230
Sleeve
(For 723-46-45100, 723-46-45500)
10
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
1
1
1
1
1
a
a
1
1
1
1
1
There are many types of the pistons.

Clean the pressure compensation valve
thoroughly. Then, using the tool, install
seals as shown in the figure.
3.
Fit O-ring (6) to piston (2).
4.
Set tool L1 to piston (2) and push it in with your

hand slowly so that seal (5) will expand evenly.
a You may push in the seal to the flat part of
the tool first, and then install the tool to the
piston and push in the seal further.
PC400, 450-7E0
5.
6.
Set tool L2 to piston (1) for other seal (3) and

push it in with your hand slowly so that seal (3)
will expand evenly.
a You may push in the seal to the flat part of
the tool first, and then install the tool to the
piston and push in the seal further.
SEN03612-01
Assembly
q
q
Install correcting tool L3 to piston (1) for about

1 minute to fit seals (2) and (3).
a Check that the seal are not projected or
broken.
7.
Apply engine oil to the sliding surfaces of the

parts before installing.
When installing spools (7) and (10) in the valve
chamber, direct drilled holes (8) and (11)
toward cylinder ports (9) and (12).
Install filters (13) to the bottom of ports PLS1

and PLS2 as shown below.
Fit plug (3) and spring (4) to piston (2) and

assemble pressure compensation valve (1).
a If these parts are difficult to install, do not
push them in forcibly, but install them to
correcting tool L3 to fit the seals, and then
install them to the piston.
a After assembling, push the piston with
your hand and check that it is returned by
only the spring force.
PC400, 450-7E0
11
SEN03612-01

3
Control valve top and bottom covers

2 Mating faces of control valve top and
bottom covers:
SEALEND 242 or equivalent
a Use 2 washers (W2) each for only 2
places of the control valve top cover.
Tighten the mounting bolts of the control valve
top and bottom covers in the following order.
(A o D o C o B)
3 Mounting bolt of control valve top and
bottom covers:
156.9 176.5 Nm {16 18 kgm}
Merge-divider valve
2 Mating face of merge-divider valve:
SEALEND 242 or equivalent
Tighten the mounting bolts of the mergedivider valve similarly to those of the control
valve covers.
3
12
Mounting bolt of back pressure valve,

boom Hi check valve, quick return
valve, lock valve, and arm plate:
58.8 73.6 Nm {6 7.5 kgm}
Mounting bolt of merge-divider valve:

156.9 176.5 Nm {16 18 kgm}
Tighten the mounting bolts of the boom Hi

check valve, quick return valve, lock valve, and
arm plate similarly to those of the control valve
covers.
PC400, 450-7E0

a When installing each pressure compensation valve, check the mark made when it
was removed.
Main relief valve assembly

After installing the main relief valve to the control valve, see Testing and adjusting, Measuring and adjusting oil pressure in work
equipment, swing, and travel circuits.
PC400, 450-7E0
SEN03612-01
13
SEN03612-01

hydraulic pump assembly
796-460-1210
Oil stopper
q 1
796-770-1320
Adapter
q 1
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
Removal
k
k
a
1.
2.
Disconnect the cable from the negative ()

terminal of the battery.
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
Put tags to the disconnected hoses and tubes
to prevent a mistake in re-connecting them.
Remove 2 lower covers (1).
Drain the oil from the flywheel housing.
4.
Open the main pump side cover.
5.
Open the engine hood.
6.
Lift off covers (2) and (3) together.
7.
Remove cover (4).
8.
Remove stay (5).
Remove the hydraulic tank strainer. Using tool

C, stop the oil.
a When not using tool C, remove the drain
plug to drain the oil from the hydraulic tank
and piping.
6
14
3.
Hydraulic tank: Approx. 335 l
PC400, 450-7E0
9.
Disconnect the following 2 pump wiring connectors.

q
(6): V22 (PC-EPC solenoid valve)
Band color: Red
q
(7): V21 (LS-EPC solenoid valve)
Band color: White
10. Disconnect the following 10 hoses and 1 tube.

q
(8): EPC basic pressure port hose
(Band color: Yellow)
q
(9): Rear pump pressure input port hose
(Band color: Red)
q
(10): Rear pump discharge port hose
q
(11): Front pump discharge port hose
q
(12): Drain port hose
q
(13): Front load pressure input port hose
q
(14): Rear load pressure input port hose
(Band color: Red)
q
(15): Front pump pressure input port hose
q
(16): Pump suction port tube
PC400, 450-7E0
SEN03612-01
11. Sling hydraulic pump assembly (18) temporarily and remove 12 mounting bolts (17).
12. Lift off hydraulic pump assembly (18).

4
[*1]
Hydraulic pump assembly: 255 kg
15
SEN03612-01
Installation
q

removal.
[*1]
2
2
Hydraulic pump involute spline:

Anti-friction compound (LM-G)
Mating face of hydraulic pump case:
Refilling with oil

3 Flywheel housing drain plug:
42.1 70.6 Nm {4.3 7.2 kgm}
level.

again.
5
16

Approx. 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
Bleeding air
various parts.
PC400, 450-7E0
SEN03612-01
Removal and installation of oil

seal in hydraulic pump input shaft1
Installation
Removal
[*1]
1.
Remove the hydraulic pump assembly. Refer

to the Removal of hydraulic pump assembly
section.
2.
Remove snap ring (1) and then remove spacer

(2).
3.
Pry off oil seal (3) with a screwdriver.

[*1]
a When attempting to pry off the seal, do not
damage the shaft.
PC400, 450-7E0

removal.
Oil seal lip portion: Grease (G2-LI)

Oil seal outer circumference: Grease (G2-LI)
a Coat the oil seal outer circumference
thinly with grease.
a Press-fit oil seal (3), using tool [1].
17
SEN03612-01

work equipment PPC valve
assembly
a
Only precautions for assembling the work

equipment PPC valve assembly are explained
below.
Disassembly
a
Spring (6) and spring (7) consists of each one

of two types of springs with different installed
loads in four places, so check the mounting
position (oil pressure port) and mark with tags
to prevent mistakes when installing.
Assembly
a
a
a
a
18
When assembling, clean and inspect the parts

closely and take care fully so that dirt, rust,
flaw, etc. will not cause a trouble.
When installing plug (2) to body (1), take care
that its tip will not enter the hole of the body 20
mm in diameter.
3 Plug (2): 4 9 Nm {0.4 0.9 kgm}
The head of plug (3) must not be projected
from the body (1) surface.
3 Plug (3): 6 11 Nm {0.6 1.1 kgm}
When installing piston (8), apply grease (G2LI) to its outside and the inside of the body (1)
hole.
Install spring (5) with its small diameter side on

the shim (4) side.
q
Diameter of spring (Inside diameter)
Small diameter side: 4.9
Large diameter side: 5.55
When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
q
Installed height: 31.9 mm (Common to
both springs)
q
Installed load:
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P3, P4): 21.6 N {2.2 kg}
3 Bolt (11):
11.8 14.7 Nm {1.2 1.5 kgm}
PC400, 450-7E0

a
When installing joint (12) to body (1), apply

LOCTITE as shown below.
1) When installing the joint, apply 1 drop
(approx. 0.02 g) of LOCTITE (No. 262)
each to 2 places of the female screw (A)
of the body. Before installing the joint,
thoroughly degrease and dry its male
screw and the female screw of the body
with DRYSOL.
2) Drop LOCTITE to the following positions.
2 Female screw (A) of body:
LOCTITE No. 262
3 Joint (12): 39 49 Nm {4 5 kgm}
Apply grease (G2-LI) to the rocking part of joint

(12) and the contact surfaces of disc (13) and
piston (8).
2 Quantity of grease (G2-LI)
1) Rocking part of joint:
2 4 cc/periphery
2) Contact surfaces of disc and piston:
0.3 0.8 cc/place
When assembling disc (13), adjust it so that
the end play of the lever will be 0.5 3 mm at
200 mm from the center of revolution.
q
See Testing and adjusting, "Adjusting play
of work equipment and swing PPC valve".
3 Nut (14): 69 88 Nm {7 9 kgm}
PC400, 450-7E0
SEN03612-01
19
SEN03612-01

travel PPC valve assembly
a
Only precautions for assembling the travel

PPC valve assembly are explained below.
a
Sketch
New/Remodel
Part Name
Qty
Part No.
Assembly
Necessity
Symbol
Special tools
1 796T-416-1010 Push tool
t 1
N Q
Q 2 796T-416-1030 Push tool
t 1
N Q
3 796T-416-1020 Push tool
t 1
N Q
20
a
a
Clean and check the parts carefully to prevent

a trouble caused by dirt, rust, flaw, etc., and
assemble them with extreme care.
When assembling piston (2), apply grease
(G2-LI) to its outside of the piston and the
inside of the hole of the body (1).
Install spring (3) with the small diameter end
on the shim (4) side.
q
Diameter of (Inside diameter) spring
Small diameter side: 4.9 mm
Large diameter side: 5.55 mm
PC400, 450-7E0

a
Using tool Q1, insert bushing (5a) in case (6)

so that dimension (A) will be as follows.
q
Dimension (A): 20.4 0.3 mm
q
Insert the bushing from the 10 chamfered
side.
q
Do not drive the bushing with direct impact
loads of a hammer etc.
Using tool Q2, insert bushing (5) in case (6).
q
Insert the bushing from the 10 chamfered
side.
q
Do not drive the bushing with direct impact
Using tool Q3, insert pin (7) in lever (9) so that

dimension (B) will be as follows.
q
Dimension (B): 0 0.5 mm
q
Do not drive the pin with direct impact
Apply grease (G2-LI) to the sliding parts of

shaft (8), contact parts of lever (9) and piston
(2), and contact parts of the lever of damper
(10) and pin (11).
2 Quantity of grease (G2-LI) applied
q
Sliding parts of shaft (8):
4 8 cc/periphery
q
Contact parts of lever (9) and piston
(2): 0.3 0.8 cc/part
q
Contact parts of lever of damper (10)
and pin (11): 0.3 0.8 cc/part
PC400, 450-7E0
SEN03612-01
a
Install washer (12) 1.6 mm thick first. If the difference of the lever stroke angle between the
right and left exceeds 0.7, replace the washer
with one of different thickness to reduce the
difference below 0.7. (If the washer thickness
is reduced by 0.3 mm, the stroke angle is
increased by 0.39.)
q
Thickness of washers: 1.0, 1.3, 1.6 mm
Install plugs (13) to body (1) after putting ball
(14) in and press fitting seat (15).
q
Install the plugs in the order of [1], [2] and
[3].
Tighten each part to the following torque.

q
Plug (16): 6 11 Nm {0.6 1.1 kgm}
q
Plug (13): 9.8 14.7 Nm {1 1.5 kgm}
q
Plug (17): 24.5 34.3 Nm {2.5 3.5 kgm}
q
Bolt (18): 19.6 27.4 Nm {2.0 2.8 kgm}
q
Screw (19): 0.441 0.588 Nm {0.045
0.06 kgm}
q
Bolt (20): 25 31 Nm {2.5 3.2 kgm}
q
Bolt (21): 27 34 Nm {2.8 3.5 kgm}
q
Plug (22): 1.27 1.67 Nm {0.13 0.17
kgm}
q
Plug (23): 4 9 Nm {0.4 0.9 kgm}
21
SEN03612-01

hydraulic cylinder assembly
Disassembly
Cylinder repair
stand
Wrench assembly t 1
790-102-4310
Pin
t 2
Expander
q 1
Ring (For boom

and bucket)
q 1
796-720-1680
4 07281-01589
Clamp (For boom

q 1
and bucket)
796-720-1690
Ring (For arm)
q 1
07281-01919
Clamp (For arm)
q 1
790-201-1702
Push tool kit
t 1
Push tool
790-201-1851
(For bucket)
N
5
Push tool
(For boom)
790-201-1871
Push tool
(For arm)
790-101-5021 Grip
01010-50816 Bolt
Push tool kit
4)
Disassemble the piston rod assembly

i) Set piston rod assembly (2) to tool N1.
1
1
t 1
790-101-5021 Grip
01010-50816 Bolt
Plate
(For bucket)
790-201-1670
Plate
(For boom)
790-201-1680
Plate
(For arm)
6 790-201-1660
22
790-201-1861
790-201-1500
Piston rod assembly

1) Remove the piping from the cylinder
assembly.
2) Remove the mounting bolts and disconnect cylinder head assembly (1).
3) Pull out piston rod assembly (2).
a Put a container under the cylinder to
receive oil.
t 1
790-102-4300
3 790-720-1000
N/R
1 790-502-1003
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
1.
ii)
a
Remove piston assembly lock screw (3).

This work is common to the boom,
arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75
PC400, 450-7E0

a
If screw (3) is so caulked that you

cannot remove it, tighten it temporarily and tap the threads on it, and
then remove it.
iii)
Using tool N2, remove piston assembly (4).

q
When not using tool N2, loosen
the piston assembly by using the
drilled holes (10: 2 places) (in
which the pins of N2 are inserted
in the following figure).
PC400, 450-7E0
SEN03612-01
iv) Remove plunger (5).

q
Perform this work for only the
boom and arm cylinder.
v) Remove collar (6).
q
boom and arm cylinder.
vi) Remove head assembly (7).
vii) Remove cap (8), 11 balls (9), and

plunger (10).
q
arm cylinder.
a Since cap (8) is made of nylon,
tighten a screw into it and pull it
with pliers.
23
SEN03612-01
2.
Disassembly of piston assembly

1) Remove rings (11).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove the O-ring and backup rings (14).
Assembly
a
a
a
3.
24
Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove snap ring (21).
6) Remove bushing (20).
1.
Take care not to damage the packings, dust

seals, O-rings, etc.
Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
Do not insert each backup ring forcibly, but
warm it in water at 50 60C and then insert it.
Assembly of cylinder head assembly

1) Using tool N5, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool N6, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).
6) Install snap ring (21).
PC400, 450-7E0
2.
Assembly of piston assembly

1) Using tool N3, expand piston ring (13).
a Set piston ring (13) to tool N3 and
t ur n th e h an dl e 8 1 0 t im e s t o
expand the piston ring.
2) Set tool N4 and contract piston ring (13).
3)
4)
5)
SEN03612-01
3.
Piston rod assembly

1) Set the piston rod to tool N1.
2) Install cylinder head assembly (7) to the
piston rod.
3) Fit the O-ring and backup ring to collar (6),
and then install them.
q
Perform this work for only the boom
and arm cylinders.
4) Install plunger (5).
q
Perform this work for only the boom
and arm cylinders.
Install backup ring and O-ring (14).

Install wear ring (12).
Install ring (11).
a Do not increase the closed gap of the
ring too much.
2
5)
Ring groove: Grease (G2-LI)
PC400, 450-7E0
Set plunger (10) to the piston rod. Install

11 balls (9) and secure them with cap (8).
a After installing the plunger, check that
it has a little play at its end.
q
Perform this work for only the arm cylinder.
25
SEN03612-01
6)
Assemble piston assembly (4) according

to the following procedure.
q
When reusing the rod and piston
assembly (4)
i) Tighten piston assembly (4). Then,
using tool N2, tighten piston assembly (4) until the screw holes are
aligned.
a Remove the burrs from the
threads with a file.
Go to iv).
iii)
Make a screw hole to install screw

(3).
a Apply a drill to the V-groove of
the threaded parts of piston (4)
and rod (2) and make a hole.
a When making a hole on the cylinder (arm cylinder) having the bottom cushion, make it around the
cushion plug.
q
Dimensions of screw hole (mm)
Tap drill diameter
Tap to be used
10.3
12 x 1.75
Tap drill
hole depth
Tapping
depth
Bucket/
Boom
27
20
Arm
36
29
iv) Tighten screw (3).

a Clean the parts thoroughly and
remove metal chips, dirt, etc.
When replacing either or both of
the rod and piston assembly (4)
with new ones
a Make a mark of the cushion plug
position on the end of the rod having
the bottom cushion.
q
Perform this work for only the arm cylinder.
ii) Using the tool, tighten piston assembly (4) until it reaches the end of the
rod.
3 Piston assembly:
294 29.4 Nm {30 3.0 kgm}
a After tightening the piston, check
that plunger (5) has some play.
q
boom and arm cylinders.
26
v)
Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 73.6 Nm {6 7.5 kgm}
Caulk the threaded part [1] by 4 places
with a punch.
PC400, 450-7E0
7)
Install piston rod assembly (2).

a Set the abutment joint of the ring at a
side and insert the piston rod, aligning
it with the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.
8)
Tighten the mounting bolts of cylinder

head assembly (7).
3
Mounting bolt:
Cylinder
name
9)
SEN03612-01
Tightening torque
Bucket
530 78.5 Nm {54.0 8 kgm}
Arm
892 137 Nm {91.0 14 kgm}
Boom
530 78.5 Nm {54.0 8 kgm}
Install the piping.
PC400, 450-7E0
27
SEN03612-01

2008 KOMATSU
All Rights Reserved
28
SEN03613-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC400, 450-7E0
SEN03613-00
Removal and installation of work

equipment assembly
1
4.
Start the engine and retract the piston rod.

a Bind the rod with wires, etc. so that it will
not be extracted and lower it onto a stand
or put a wood block to the bottom side so
that the cylinder will not lower. When putting the wood block, remove the grease fitting on the bottom side.
a Disconnect the boom cylinder on the
opposite side similarly.
a When slinging the boom cylinder, if the
sling interferes with the work equipment
lamp, remove the work equipment lamp.
5.
Disconnect intermediate connector A42 (6) for

the work equipment lamp.
6.
Disconnect 3 arm cylinder hoses (7) and 2

bucket cylinder hoses (8).
a Put oil stopper plugs and secure the
hoses to the valve side with ropes.
7.
Sling work equipment assembly (12) temporarily.
8.
Remove cover (9), plate (10), and foot pin (11)

to disconnect work equipment assembly (12).
[*3]
796-670-1100
Remover
N/R
Sketch
Part name
Qty
Part number
Necessity
Symbol
Special tools
q 1
796-670-1110 Sleeve
796-670-1120 Plate
796-670-1130 Screw
796-870-1110 Adapter
01643-33080 Washer
01803-13034 Nut
790-101-4000
Puller
q 1
(490 kN {50t}, long)
790-101-1102
Pump
(294 kN {30t})
q 1
Removal
k
Extend the arm and bucket fully, lower the

work equipment to the ground, and set the
work equipment lock lever to the LOCK
position.
See Testing and adjusting, Releasing residual pressure from hydraulic circuit.
1.
Disconnect grease hose (1).
2.
Sling boom cylinder assembly (2) temporarily

and remove lock bolt and nut (3).
[*1]
3.
Remove plate (4) and head pin (5).

[*2]
a Check the quantity and positions of the
inserted shims.
PC400, 450-7E0
9.
When removing with tool P

Remove plate (10). Sling and set tool P
and remove foot pin (11) to disconnect
work equipment assembly (12).
Check the quantity and positions of the
inserted shims.
Move the machine in reverse to remove work

equipment assembly (12).
4
Work equipment assembly:

PC400-7E0, PC400LC-7E0: 7,400 kg
PC450-7E0, PC450LC-7E0: 8,400 kg
PC400, 450-7E0
SEN03613-00
Installation
q

removal.
[*1]
a Tighten the locknut so that clearance (a)
between the plate and nut will be 0.5 1.5 mm.
[*2]
Inside wall of bushing before assembling pin:

Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance (b)
between cylinder rod (12) and plate (4) will be
1.5 mm or less.
Standard shim: 1.0, 2.0 mm
SEN03613-00
[*3]
Inside wall of bushing before assembling pin:

Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance (c)
between boom (13) and bracket (14) will be 1
mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
Bleeding air
various parts.

again.
PC400, 450-7E0
PC400, 450-7E0
SEN03613-00
SEN03613-00

2008 KOMATSU
All Rights Reserved
SEN03614-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Removal and installation of operators cab ..................................................................................................... 2
Removal and installation of operators cab glass (stuck glass) ...................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
PC400, 450-7E0
SEN03614-00

operators cab
1.
5.
Remove air conditioner connector plate (14).
6.
Disconnect connectors M71 (15), H10 (16),

H11 (17), and H12 (18).
7.
Disconnect upper and lower duct joints (19)

and (20).
8.
Remove controller sub-plate (21) and incline it

against the air conditioner.
9.
Remove cover (22) and floor mat (23).

Remove rear covers (1), (2), (3), and (4).
2.
Remove duct (5), cover (6), and plate (7).
3.
Remove plate (8), duct (9) and the element.

a Remove the duct lock clip.
Remove clip (10) and disconnect cab wiring

connectors M45 (11), H08 (12), and H09 (13).
Removal
k
4.
PC400, 450-7E0
SEN03614-00
10. Move right console (24) into the cab.
15. Disconnect radio antenna (31).
11. Remove monitor panel undercover (25).
16. Remove clip (32) and take wiring harness (33)

out of grommet (34).
12. Disconnect cab wiring connector W04 (26)

(Wiper motor).
13. Remove ducts (27) and (28).
a Both (27) and (28) are 2 in number.
a Cut the tie-wrap on the monitor wiring harness.
14. Remove cover (29) and monitor assembly
(30).
PC400, 450-7E0
17. Take grommet (35) out of the right front of the

cab.
18. Disconnect the windshield washer hose from
(36).
19. Remove 4 mounting bolts (37) and 5 mounting
bolts (38).
a Check the types of the bolts.
a In the initial period, 7 mounting bolts (38)
are used.
SEN03614-00
20. Using lever block [1], lift off operator's cab

assembly (39).
4
Operator's cab assembly: 300 kg
Installation
q

removal.
21. When starting the engine while the operator's

cab is removed (for transportation, etc.), use
the following brackets.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
2)
Bracket (42) for monitor panel assembly

(30)
Part No.: 208-53-13910
PC400, 450-7E0
SEN03614-00
Removal and installation of operators cab glass (stuck glass)
Among the panes of window glass on the 4

sides of the operator's cab, 4 panes (1) (4)
are stuck.
In this section, the procedure for replacing the
stuck glass is explained.
When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the operator's cab.)
For the procedure for replacing the front window assembly, see Removal and installation
of front window assembly.
PC400, 450-7E0
(1) : Right side window glass

(2) : Left side rear window glass
(3) : Door lower window glass
(4) : Front window glass
(5) : Front window assembly
(Front window glass + Front frame)
(6) : Both-sided adhesive tape
(16): Center trim seal
SEN03614-00
1 793-498-1210
Lifter
(Suction cup)
t 2
2 20Y-54-13180
Adapter
t 2
N/R
Sketch
Part name
(The figure shows the operator's cab of a

wheel loader.)
Qty
Part number
Necessity
Symbol
Special tools
Removal
a
Remove the window glass to be replaced

1.
Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab
(metal sheet) (8).
a
a
If the window glass is broken finely, it may

be removed with knife [4] and a screwdriver.
Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].
wheel loader.)
If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc.
(or hold them by winding them onto something) and move the wire to the right and
left to cut the adhesive and both-sided
adhesive tape. Since the wire may be
broken by the frictional heat, apply lubricant to it.
2.
Remove the window glass.
PC400, 450-7E0
Installation
1.
Using a knife and scraper [5], remove the

remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operator's cab.
a Remove the adhesive and both-sided
adhesive tape to a degree that they will
not affect adhesion of the new adhesive.
Take care not to scratch the painted surf a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e
scratched, adhesion will be lowered.)
wheel loader.)
2.
SEN03614-00
3.
Apply primer (10).

a The using limit of primer (10) is 4 months
after the date of manufacture. Do not use
primer (10) after this limit.
a Use the primer within 2 hours after
unpacking it.
a Even if the primer is packed again just
after it is unpacked, use it within 24 hours
after it is unpacked for the first time. (Disc ar d t h e p r i m e r 2 4 ho u r s a ft e r i t i s
packed.)
1) Stir the primers for paint and glass sufficiently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room temperature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
wheel loader.)
PC400, 450-7E0
SEN03614-00
3)
Evenly apply paint primer to the surfaces

to stick both-sided adhesive tapes and the
surfaces out of those surfaces on operator's cab (8) which will be coated with the
adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be lowered.)
a
q

a
q
q
Parts to be coated with primer: Apply

the primer all over dimension (a).
Dimension to apply primer (a): 25 mm
In addition to the above parts, apply

the primer to right side window glass
(1) and door lower window glass (3).
Range to apply primer additionally for
right side window glass (1): (b)
Range to apply primer additionally for
door lower window glass (3): (c)
After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
Never apply wrong primer. If the glass

primer is applied by mistake, wipe it
off with white gasoline.
PC400, 450-7E0
4)
Evenly apply glass primer to the sticking

surfaces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be lowered.)
a
a
Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (9) and all over dimension (d) which will be on both-sided
adhesive tape (6) and operator's cab
(8).
Do not apply the primer to the
boarder about 5 mm wide between
the black part and transparent part of
the glass.
After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
Never apply wrong primer. If the
glass primer is applied by mistake,
wipe it off with white gasoline.
PC400, 450-7E0
SEN03614-00
4.
Stick both-sided adhesive tape (6) along the

inside edge of the glass sticking section.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window
frame.
1)
When sticking both-sided adhesive tape

(6) around a frame, do not lap its finishing
end over the starting end but make clearance (e) of about 5 mm between them.
Stick both-sided adhesive tape (6) for right
side window glass (1) as shown in the figure.
SEN03614-00
a
q
2)
3)
10

a
Stick both-sided adhesive tape (6a) additionally for right side window glass (1).
Positions to stick additional both-sided
adhesive tape for right side window glass:
(f) : 50 mm
(g) : 90 mm
(h) : 250 mm
Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure.
4)
Stick both-sided adhesive tape (6b)

additionally for door lower window
glass (3).
Positions to stick additional bothsided adhesive tape for door lower
window glass:
(j) : 110 mm
(k) : 90 mm
(m) : 200 mm
Stick both-sided adhesive tape (6) for front

window glass (4) as shown in the figure.
Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the
figure.
PC400, 450-7E0

a
SEN03614-00
Stick both-sided adhesive tape (6c) of

the lower side of the front window
glass along the outside edge of the
lower line, differently from other bothsided adhesive tapes (6). (If it is stuck
al ong the inside, it will be s een
through the transparent part of the
glass.)
5.
Position the new window glass.

1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then
adjust it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning line (n).
a Stick tapes [6] to the right, left, and
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass for accurate
positioning.
3) Cut the tape between window glass (9)
and operator's cab (8) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
PC400, 450-7E0
6.
When positioning front window glass

(4), set its horizontal position to the
frame width and set its vertical position so that height difference (p)
between it and the frame top will be 3
mm.
Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25C.
a Never heat the adhesive higher than
30C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
11
SEN03614-00
1)
2)
Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the
nozzle.
Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as follows.
q
Dimension (q): 10 mm
q
Dimension (r) : 15 mm
4)
5)
Remove the release tape of the bothsided adhesive tape on the glass side.
Apply adhesive (15) to the outside of bothsided adhesive tape (6) of the operator's
cab.
a
a
3)
12
Apply adhesive (15) to dimensions (s)

and (t) of both-sided adhesive tape
(6) of operator's cab (8).
q
Dimension (s): 10 mm
q
Dimension (t) : 15 mm
Apply adhesive (15) higher than bothsided adhesive tape (6).
Apply the adhesive evenly.
Set adhesive cartridge (12) to caulking

gun [7].
a An electric caulking gun is more efficient.
PC400, 450-7E0

a
SEN03614-00
Apply adhesive (15) additionally for

additional both-sided adhesive tape
(6a) of the right side window glass
and additional both-sided adhesive
tape (6b) of door lower window glass.
7.
Install the window glass.

1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
PC400, 450-7E0
You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suction cup Y1.
After installing front window glass (4),

fill the clearances between it and center trim seal (16) with caulking material in range (s) to dimensions (t) and
(u).
After applying the primer to glass (4)
of section (A) (A), apply adhesive
as caulking material.
q
Caulking dimension (t) : 2 mm
q
Caulking dimension (u) : 5 mm
a When caulking, mask the glass side
and form the adhesive with a rubber
spatula as shown in the figure.
a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
13
SEN03614-00
2)
8.
Fix the window glass.

1) After installing right window glass (1) to
the operator's cab, insert stopper rubbers
Y2 to 2 places (v) at the bottom of the
glass to fix the glass.
9.
Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and bothsided adhesive tape to fit them completely.
After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhesive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20C and humidity of 60%).
2) After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
14
PC400, 450-7E0
Removal and installation of front

window assembly
1
k

To replace the front window glass, the front
window assembly must be removed from the
operator's cab. The procedure for removing
and installing the front window assembly (front
frame and front window glass) is explained
below.
SEN03614-00
5.
Release the rear locks.
6.
Lower the front window assembly carefully a

little. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
7.
Remove rollers (8) and (9) under the both

sides of the front window.
Removal
1.
Raise the front window assembly to the ceiling

and fix it with the rear locks (on both sides).
2.
Remove left corner blocks (1) and (2) and right

corner block (3).
[*1]
3.
Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block
bracket (7).
[*2]
4.
Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
a This bolt will be used to hang the pull-up
assist cable in step 8.
PC400, 450-7E0
15
SEN03614-00
8.
Remove left lower pin (10).

[*3]
a If left lower pin (10) is removed, plate (12)
at the end of pull-up assist cable (11)
comes off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator's
cab. Accordingly, take care when
removing left lower pin (10) to disconnect pull-up assist cable (11).
10. Lower front window assembly (13) completely.

a Do not let the front window assembly
touch the monitor.
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front window assembly (13).
9.
16
Put out the bottom of front window assembly

(13) through the rail opening portion and lower
it gradually.
PC400, 450-7E0
SEN03614-00
Installation
q

removal.
[*1] [*2]
Adjust opening and closing of the front window
assembly according to the following procedure.
PC400, 450-7E0
1.
Open and close the front window to check that

it does not interfere with the rails and the rollers are not hitch.
2.
If there is any problem in opening or closing of

the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
3 Mounting bolt: 9.8 Nm {1.0 kgm}
17
SEN03614-00
3.
Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are applied securely.
4.
Install right corner block (3) and fix right corner

block bracket (7) with right striker bolt (5).
a Tighten the striker bolt securely after
adjusting it in step 6.
a Install the right corner block so that there
will be no level difference at part (a).
a Install the right corner block so that level
difference (b) between the rail and right
corner block (3) at part PF will be 0 1.0
mm. Check that the right corner block is
not projected from the rail at the rolling
surface of the roller.
a Secure roller clearance (c) at part PJ.
18
5.
Install left corner blocks (1) and (2) and secure

left corner bracket (6) with left striker bolt (4).
a Tighten the striker bolt securely after
adjusting it in step 6.
a Install the left corner blocks so that there
will be no level difference at 2 part (d).
a Secure roller clearance (e).
PC400, 450-7E0
6.
SEN03614-00
Adjust the striker bolts according to the following procedure (Adjust the "CLOSE" positions
of the front window assembly locks).
1) Tighten left striker bolt (4) and right striker
bolt (5) at roughly right positions so that
front window glass (18) will be fitted to
cab-side trim seal (19).
2)
7.
PC400, 450-7E0
Open and close the front window assembly and check the working condition of
both locks (20) and (21).
i) If both locks do not work normally,
move the striker bolts toward the rear
of the cab and tighten them again.
ii) After moving the striker bolts, check
the fitness of the front window glass
and cab-side trim seal which was
checked in step 6.
iii) Repeat the work in i) and ii) until the
fitness of the front window and the
working condition of both locks (20)
and (21) are acceptable, and then
tighten the striker bolts.
After adjusting the striker bolts, splash water

heavily over the front window glass and check
that the water does not leak into the cab.
19
SEN03614-00
8.
Adjust the "opening" lock of the front window

assembly.
1) After adjusting the "closing" lock of the
front window in step 6, raise the front window assembly to the ceiling.
2) Set the right and left front window assembly locks at the rear of the operator's cab
to the "OPEN" positions, and then check
the following items.
q
Check that right and left locks (20)
and (21) are closed normally.
q
Check that right and left locks (20)
and (21) are inserted in parallel in
right and left striker plates (22).
q
Check that right and left rubber stoppers (24) are in contact with the front
window assembly and their deflection allowance is 1.5 3.0 mm.
3) After checking the above items, if necessary, adjust them by moving right and left
striker plates (22) at the rear of the operator's cab.
9.
Adjust the front window stoppers.

1) After adjusting "closing" lock of the front
window assembly in step 9, check the
contact of both front window stoppers
(23).
2) If both stoppers (23) do not contact normally, adjust and fix them at places where
they contact normally.
10. Check the latching effort of the front window

assembly.
1) After finishing steps 6 9, check that
latching efforts of both locks (20) and (21)
are even.
a Check the latching efforts on both
"closing" side (in the front of the operator's cab) and "opening" side (in the
rear of the operator's cab).
[*3]
20
Left lower pin: 27 34 Nm {2.75 3.47 kgm}

Mounting bolt: Adhesive (LT-2)
PC400, 450-7E0
PC400, 450-7E0
SEN03614-00
21
SEN03614-00

2008 KOMATSU
All Rights Reserved
22
SEN03615-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and Installation of KOMTRAX terminal assembly ............................................................................ 4
Removal and installation of monitor assembly................................................................................................ 5
Removal and installation of pump controller ................................................................................................... 6
PC400, 450-7E0
SEN03615-01
Removal and installation of air

conditioner unit assembly
3.
Remove duct (5), cover (6), and plate (7).
4.
Remove plate (8) and duct (9).

a Remove the duct lock clip.
5.
Remove ducts (10) and (11).
6.
Disconnect connectors D01 (12), D02 (13),

C09 (14), R22 (15), R20 (16), and K19 (17).
7.
Remove and sling controller (18).
8.
Remove plate (19).
9.
Disconnect air conditioner unit connectors M27

(20) and M33 (21).
Removal
k
k
a
a
k

In the case that you do not drain the coolant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
Ask professional traders for collecting and filling operation of refrigerant (R134a).
Never release the refrigerant (R134a) to the
atmosphere.
If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. Accordingly, put
on protective goggles while you are collecting the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
1.
Swing the upper structure by 90.
2.
Remove rear covers (1), (2), (3), and (4).
PC400, 450-7E0
10. Remove the air conditioner unit undercover.

a Part A
SEN03615-01
Installation
q

removal.
a When installing the air conditioner circuit
hoses, take care that dirt, water, etc. will
not enter them.
a When connecting each air conditioner
hose, check that the O-ring is fitted to the
joint.
a Check that each O-ring is free from flaw
and deterioration.
[*1]
a Apply compressor oil (ND-OIL8) to the threads
of the refrigerant pipe joints and tighten each
nut with double spanner.
11. Remove mounting bolt (24) and connector
(25).
[*1]
12. Disconnect heater hoses (22) and (23) and air
conditioner tube (26).
[*1]
a Put tags to the disconnected hoses and
tubes to prevent a mistake when re-connecting them.
Hose clamp (M6 bolt):

8 12 Nm {0.8 1.2 kgm}
Hose screw of M16 x 1.5:
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}
Filling air conditioner circuit with refrigerant (R134a)

Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 950 50 g
13. Remove the 7 mounting bolts and air conditioner unit assembly (27).
PC400, 450-7E0
SEN03615-01
Removal and Installation of

KOMTRAX terminal assembly
Installation

removal.
Removal
k
1.
Remove covers (1), (2), and (3).
2.
Disconnect GPS connector (4) and antenna

wire (5).
3.
Disconnect connector G01 (6).
4.
Remove 4 mounting bolts and

KOMTRAX terminal assembly (7).
remove
PC400, 450-7E0

monitor assembly
SEN03615-01
Installation

removal.
Removal
k

1.
Remove cover (1) and disconnect wiring connector P15 of air conditioner sunlight sensor
(2).
a Raise and remove the cover.
2.
Remove the 3 mounting screws and monitor

assembly (3).
a Disconnect monitor panel wiring connectors P01, P02, and P70 before removing
the monitor assembly.
PC400, 450-7E0
SEN03615-01
Removal and installation of pump

controller
1
Installation
q

removal.
Removal
k

1.
Remove covers (1), (2), and (3).
2.
Disconnect pump controller wiring connectors

C01 (4), C02 (5), and C03 (6).
3.
Remove the 4 mounting bolts and pump controller assembly (7).
PC400, 450-7E0
PC400, 450-7E0
SEN03615-01
SEN03615-01

2008 KOMATSU
All Rights Reserved
SEN03618-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Hydraulic circuit diagram................................................................................................................................. 3
PC400, 450-7E0
SEN03618-00
PC400, 450-7E0
Hydraulic circuit diagram PC400, 400LC-7E0, PC450, 450LC-7E0
Hydraulic circuit diagram

PC400, 400LC-7E0, PC450, 450LC-7E0
SEN03618-00
PC400, 450-7E0
PC400, 450-7E0
SEN03618-00
SEN03618-00

2008 KOMATSU
All Rights Reserved
SEN03617-00
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model
Serial number
PC400-7E0
60001 60089
65001 and up
60001 60089
65001 and up
30001 30058
65001 and up
30001 30058
65001 and up
PC400LC-7E0
PC450-7E0
PC450LC-7E0

Electrical circuit diagram ................................................................................................................................. 3
Connector arrangement diagram .................................................................................................................... 5
PC400, 450-7E0
SEN03617-00
PC400, 450-7E0
Electrical circuit diagram PC400, 400LC-7E0, PC450, 450LC-7E0
Electrical circuit diagram

PC400, 400LC-7E0, PC450, 450LC-7E0
SEN03617-00
PC400, 450-7E0
Connector arrangement diagram

PC400, 400LC-7, PC450, 450LC-7E0
Connector arrangement diagram

Address of
stereogram
Connector
No.
Model
Number
of pins
Intermediate connecter
V-1
P01
070
12
Monitor panel
P-6
W-1
P01
AMP
Bucket CURL pressure sensor
L-2
DT
12
Q-1
P02
040
20
Monitor panel
P-5
A04
SWP
R-1
P02
Boom LOWER pressure switch
L-2
A05
SWP
14
W-1
P03
Swing RIGHT pressure switch
L-2
A06
SWP
14
Q-1
P04
AMP
Arm IN pressure sensor
L-2
A07
SWP
16
V-1
P05
Bucket DUMP pressure switch
L-1
A09
SWP
P-2
P06
Boom RIGHT pressure switch
L-1
A13
DT
Intermediate connector (to boom working lamp)
P-1
P07
Swing LEFT pressure switch
L-1
A22
DT
Rear working lamp
H-9
P08
Arm OUT pressure switch
L-1
CE02
DRC
50
Engine controller
AK-5
P09
Travel hydraulic pressure switch (Black)
R-1
CE03
DRC
Engine controller
AK-6
P10
Travel hydraulic pressure switch (Steering signal) (Red)
R-1
CN1
DT
No. 1 fuel injector
AK-9
P13
CN2
DT
No. 2 fuel injector
AK-9
P15
CN3
DT
No. 3 fuel injector
AL-9
P16
CN4
DT
No. 4 fuel injector
AN-7
P17
CN5
DT
No. 5 fuel injector
AN-7
P20
CN6
DT
No. 6 fuel injector
AN-7
CP01
DRC
24
Pump controller
CP02
OTP
40
Pump controller
CP03
DRC
40
Pump controller
D01
SWP
Concentrated diode
D02
SWP
Concentrated diode
D10
D11
Connector
No.
Model
Number
of pins
A01
A02
A03
Component name
Component name
Address of
stereogram
Intermediate connector
K-3
Air conditioner daylight sensor
P-6
Bottom dump close switch (Loading shovel spec.)
L-4
Air conditioner high-pressure switch
W-9
Fuel control dial
R-8
P21
Fuel level sensor
D-9
Y-9
P22
Hydraulic oil temperature sensor
K-3
X-9
P23
Air cleaner clogging sensor
G-9
X-9
P24
Radiator coolant level sensor
AJ-1
AB-2
P25
AMP
F pump oil pressure sensor
L-4
AB-2
P26
AMP
R pump oil pressure sensor
K-3
Diode
AA-8
P30
Bottom dump open switch (Loading shovel spec.)
L-4
Diode
AA-8
P44
Engine oil level switch
AK-5
EGR
DT
EGR valve
AJ-9
P70
040
16
Monitor panel
ENG
DRC
60
Engine controller
AK-6
PAMB
FRAMATOME
Atmospheric pressure sensor
AM-9
20
Fuse
X-2
PFUEL
AMP
AL-5
F01
P-4
F02
Revolving warning lamp (if equipped)
AB-9
PIM
CANNON
AN-6
F04
Fusible link (65A)
B-6
POIL
FRAMATOME
Engine oil pressure sensor
AJ-6
F05
Fusible link (30A)
E-2
PCV1
SUMITOMO
Fuel supply pump PCV1
AJ-6
SUMITOMO
Engine G sensor
AJ-6
PCV2
SUMITOMO
Fuel supply pump PCV2
AJ-6
G01
DRC
40
KOMTRAX
Y-9
R01
Terminal
Battery relay (Terminal E)
B-6
G02
(Male) for inspection
Y-9
R02
Terminal
Battery relay (Terminal BR)
B-7
G03
(Female) for inspection
Y-9
R03A
Terminal
Battery relay (Terminal M)
D-6
G04
(Male) for inspection
Z-9
R03B
Terminal
Battery relay (Terminal M)
D-6
G05
(Female) for inspection
Z-9
R04
Terminal
Battery relay (Terminal B)
D-7
H06
090
20
Intermediate connector (to right console upper wiring harness)
Q-8
R05
Relay
Light relay
S-8
H07
Chassis ground (Floor frame)
W-2
R06
Relay
Starting motor cutout relay (PPC lock)
S-9
H08
Intermediate connector (Speaker)
AA-6
R07
Relay
Starting motor cutout relay (Personal code)
T-9
H09
Intermediate connector (Light)
AA-5
R08
Relay
Horn relay
H10
16
Intermediate connector (Monitor panel)
W-9
R15
Terminal
Intake air heater relay (Inlet)
C-5
H11
16
V-9
R16
Terminal
Intake air heater relay (Outlet)
D-5
H12
12
V-9
R17
Terminal
Intake air heater relay (Drive coil inlet)
B-6
J01
20
Joint connector (Black)
Y-2
R18
Relay
Intake air heater relay (Drive relay)
Z-2
J02
20
Joint connector (Black)
Y-3
R20
Relay
ATT circuit selector relay
Z-2
J03
20
Joint connector (Green)
Y-3
R23
Relay
Engine power supply relay (1)
Z-2
J04
20
Joint connector (Green)
Z-3
R24
Relay
Engine power supply relay (2)
Z-1
J05
20
Joint connector (Pink)
Z-3
R30
SUMITOMO
Air conditioner blower relay
AA-4
J06
20
Joint connector (Orange)
Z-3
R31
AMP
Air conditioner compressor relay
AA-7
J07
20
Joint connector (Orange)
Z-3
RES
DT
Resistance (620z)
AN-8
CAN connector
AM-9
S01
Terminal
Starting switch
R-8
JM01
Centralized terminals (Engine)
AL-9
S02
Light switch
S-8
JM02
12
AL-9
S04
Swing lock switch
S-9
JM03
10
AN-8
S05
T-9
J1939
DT
AB-1
K01
Resistor (30z)
Z-1
S07
Revolving warning lamp switch
X-2
K02
DT
CAN terminal resistance
AJ-6
S10
090
Horn switch
R-8
K31
CAN terminal resistance
P-4
S10
Pressure switch for service switch (Front) (if equipped)
J-3
Working lamp (Right front)
E-9
S11
090
Knob switch (Left)
W-1
Working lamp (if equipped)
C-2
S11
Pressure switch for service switch (Rear) (if equipped)
K-3
L01
L02
L09
Working lamp (Boom)
J-9
S14
PPC oil pressure lock switch
V-1
M01
PA
Radio
W-2
S21
Terminal
Emergency pump drive switch
U-9
M06
KES
L-4
S22
Terminal
Swing holding brake release switch
T-9
M07
090
Horn (High tone)
F-1
S25
090
16
Intermediate connector (to right console emergency switch)
U-9
M08
090
Horn (Low tone)
E-1
S30
Model selection connector
Z-2
M09
Optional power supply
AA-4
S41
DT
Switch box (Fuel priming pump) (if equipped)
M10
AA-6
SEGR
DT
EGR valve position sensor
M11
DC/DC converter
AA-6
T01
Terminal
Floor frame ground
M12
Service connector
AA-7
T03
Terminal
Radio body ground
V-9
M13
Speaker (Right)
AG-8
T04
Terminal
Revolving frame ground
H-1
M14
Travel alarm
J-2
T05
Terminal
H-1
M17
Starting motor (S/R terminal circuit)
AI-1
T06
Terminal
I-2
M18
Terminal
Alternator R terminal
AK-1
T07
Terminal
I-2
Cigarette lighter
P-3
T08
Terminal
D-2
M19
AJ-9
Y-3
M20
Terminal
Starting motor B terminal
AI-1
T09
Terminal
I-2
M21
Terminal
Alternator B terminal
AL-1
T10
Terminal
J-2
M22
Terminal
Alternator E terminal
AK-1
T11
Terminal
CAB ground
AH-3
M23
Terminal
Intake air heater
AK-9
T11
Terminal
Engine body ground
AL-5
M24
Fuel priming pump (if equipped)
T12
Terminal
Alternator ground
AJ-1
M25
Fuel priming pump (if equipped)
F-9
TFUEL
PACKARD
Fuel temperature sensor
AL-5
M26
12
Air conditioner harness
AA-4
TIM
PACKARD
AM-9
M27
18
AA-5
TWTR
PACKARD
Coolant temperature sensor
AJ-1
M29
20
Air conditioner control unit
X-2
V01
DT
M-5
M30
16
Air conditioner control unit
X-2
V02
DT
M-5
AA-5
V03
DT
M-5
V04
DT
Travel speed solenoid valve (Hi/Lo)
M-5
H-9
V05
DT
Swing holding brake solenoid valve
M-4
M33
M33
M34
M40
Light switch (if equipped)
AD-8
V06
DT
M-4
M41
Light switch (if equipped)
AC-7
V07
DT
ATT return selector solenoid valve (if equipped)
M-3
M45
DT
12
Network bus
AA-7
V08
DT
M-4
M71
Room lamp
AD-8
V11
DT
PC-EPC solenoid valve
L-6
M72
DC/DC converter
V19
DT
LS-EPC solenoid valve
L-7
M73
Speaker (Left)
M79
12V outlet
AH-8
V20
DT
Bottom dump close solenoid valve (Loading shovel spec.)
L-4
Z-8
V21
DT
Bottom dump open solenoid valve (Loading shovel spec.)
L-4
M81
Bucket quick coupler control box (if equipped)
V30
ATT flow adjustment EPC solenoid valve (if equipped)
S-1
M81
Bucket quick coupler solenoid (if equipped)
W03
Rear limit switch
AF-9
N01
W04
Wiper motor
AC-4
NE
FRAMATOME
Y-9
Engine NE sensor
AL-5
SEN03617-00
PC400, 450-7E0
PC400, 450-7E0
SEN03617-00
SEN03617-00

2008 KOMATSU
All Rights Reserved

PC450 7e0

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

PC450 7e0

Încărcat de

Drepturi de autor:

Formate disponibile

SEN03578-01

00 Index and foreword

00 Index and foreword

Organization list of the shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

00 Index and foreword

Troubleshooting of engine (S-mode)

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

00 Index and foreword

Hydraulic system, Part 3

00 Index and foreword

Adjusting play of work equipment and swing PPC valves ....................................................... 47

00 Index and foreword

Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 47

00 Index and foreword

Failure code [DWJ0KA] Merge-divider Sol. Disc. .................................................................... 32

00 Index and foreword

H-7 Boom moves slowly or lacks power .................................................................................. 13

00 Index and foreword

Removal and installation of hydraulic oil cooler assembly....................................................... 30

00 Index and foreword

PC400, 450(LC)-7E0 Hydraulic excavator

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

00 Index and foreword

How to read the shop manual

Revision and distribution

00 Index and foreword

Revised edition mark

Weight of parts of component or parts. Caution necessary when