PC400-7EO PC450-7EO Série 65001 e Acima

SEN03578-03
HYDRAULIC PC400 -7E0

EXCAVATOR
PC400LC -7E0
PC450 -7E0
PC450LC -7E0
PC400-7E0- 60001–60089
65001 and up
PC400LC-7E0- 60001–60089
65001 and up
SERIAL NUMBERS
PC450-7E0- 30001–30058
65001 and up
PC450LC-7E0- 30001–30058
65001 and up
SEN03580-03
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
Machine model Serial number
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC400, 450-7E0 1
SEN03580-03 00 Index and foreword
Composition of shop manual 1

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 accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN03578-03
00 Index and foreword ......................................................................................................... SEN03579-03

Index ............................................................................................................................... SEN03580-03 q
Foreword and general information .................................................................................. SEN03581-02
01 Specification.................................................................................................................... SEN03582-00
Specification and technical data...................................................................................... SEN03583-00
10 Structure, function and maintenance standard ............................................................... SEN03584-02

Engine and cooling system ............................................................................................. SEN03585-00
Power train...................................................................................................................... SEN03586-00
Undercarriage and frame ................................................................................................ SEN03587-00
Hydraulic system, Part 1 ................................................................................................. SEN03588-00
Work equipment.............................................................................................................. SEN03591-00
Cab and its attachments ................................................................................................. SEN03592-00
Electrical system ............................................................................................................. SEN03593-02 q
20 Standard value table ....................................................................................................... SEN03594-02

Standard service value table........................................................................................... SEN03595-02 q
30 Testing and adjusting ...................................................................................................... SEN03596-02

Testing and adjusting, Part 1........................................................................................... SEN03597-02
40 Troubleshooting .............................................................................................................. SEN03599-02

Failure code table and fuse locations ............................................................................. SEN04150-02 q
Information related to troubleshooting ............................................................................ SEN03600-02 q
Troubleshooting by failure code (Display of code), Part 1 .............................................. SEN03601-02 q
Troubleshooting by failure code (Display of code), Part 2 .............................................. SEN03602-01
Troubleshooting of electrical system (E-mode)............................................................... SEN03604-01 q
Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN03605-01
2 PC400, 450-7E0
00 Index and foreword SEN03580-03
Troubleshooting of engine (S-mode) .............................................................................. SEN03606-01
50 Disassembly and assembly ............................................................................................ SEN03607-03

General information on disassembly and assembly ....................................................... SEN03608-03 q
Engine and cooling system............................................................................................. SEN03609-02
Power train...................................................................................................................... SEN03610-02
Undercarriage and frame.................................................................................................SEN03611-02 q
Hydraulic system ............................................................................................................ SEN03612-02
Electrical system............................................................................................................. SEN03615-02
90 Diagrams and drawings .................................................................................................. SEN03616-01

Hydraulic diagrams and drawings................................................................................... SEN03618-00
Electrical diagrams and drawings ................................................................................... SEN03617-01
PC400, 450-7E0 3
Table of contents 1
00 Index and foreword
Index ............................................................................................................................... SEN03580-03
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information .................................................................................. SEN03581-02
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
Specification and technical data...................................................................................... SEN03583-00
Specification dimension drawings............................................................................................ 2
Specifications........................................................................................................................... 6
Weight table ............................................................................................................................. 12
Table of fuel, coolant and lubricants ........................................................................................ 16
10 Structure, function and maintenance standard

Engine and cooling system ............................................................................................. 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
Undercarriage and frame ................................................................................................ SEN03587-00
Track frame and recoil spring .................................................................................................. 2
Idler.......................................................................................................................................... 4
Carrier roller............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
Hydraulic equipment layout drawing........................................................................................ 2
Hydraulic tank and filter ........................................................................................................... 4
Hydraulic pump........................................................................................................................ 6
Control valve............................................................................................................................ 2
CLSS ....................................................................................................................................... 26
Functions and operation by valve ............................................................................................ 30
Merge-divider valve ................................................................................................................. 47
Attachment circuit selector valve ............................................................................................. 72
Holding valve ........................................................................................................................... 74
4 PC400, 450-7E0
Hydraulic system, Part 3................................................................................................. 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 ...................................................................................................................... 2
Dimensions of components ..................................................................................................... 6
Air conditioner piping ............................................................................................................... 2
Electrical system............................................................................................................. SEN03593-02
Engine control.......................................................................................................................... 2
Electronic control system......................................................................................................... 11
Monitor system ........................................................................................................................ 36
Sensor ..................................................................................................................................... 54
KOMTRAX system .................................................................................................................. 57
20 Standard value table

Standard service value table........................................................................................... SEN03595-02
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
30 Testing and adjusting

Testing and adjusting, Part 1 .......................................................................................... SEN03597-02
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
Bleeding air from fuel circuit .................................................................................................... 24
Checking fuel circuit for leakage.............................................................................................. 26
Checking and adjusting fan belt and alternator belt tension.................................................... 27
Checking and adjusting air conditioner compressor belt tension ............................................ 28
Measuring swing circle bearing clearance............................................................................... 29
Checking and adjusting track shoe tension ............................................................................. 30
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits............... 31
Measuring control circuit basic pressure ................................................................................. 35
Checking and adjusting pump PC control circuit oil pressure ................................................. 36
Checking and adjusting pump LS control circuit oil pressure .................................................. 39
Measuring solenoid valve output pressure .............................................................................. 44
PC400, 450-7E0 5
Measuring PPC valve output pressure .................................................................................... 47

Adjusting play of work equipment and swing PPC valves ....................................................... 48
Inspecting locations of hydraulic drift of work equipment ........................................................ 49
Releasing residual pressure from hydraulic circuit .................................................................. 51
Measuring oil leakage amount................................................................................................. 52
Bleeding air from various parts ................................................................................................ 55
Special functions of machine monitor ...................................................................................... 2
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
Failure code table and fuse locations ............................................................................. SEN04150-02
Failure codes table .................................................................................................................. 2
Before carrying out troubleshooting when failure code is displayed........................................ 6
Information related to troubleshooting ............................................................................ SEN03600-02
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
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 .......................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 36
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 38
Failure code [CA221] Ambient Press Sens High Error ............................................................ 40
Failure code [CA222] Ambient Press Sens Low Error............................................................. 42
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 43
Failure code [CA234] Eng Overspeed ..................................................................................... 45
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 46
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 48
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 50
6 PC400, 450-7E0
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 51

Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 52
Failure code [CA273] PCV2 Short Error .................................................................................. 54
Failure code [CA274] PCV2 Open Error.................................................................................. 55
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error............................................................ 56
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 .................................................................... 12
Failure code [CA449] Rail Press Very High Error .................................................................... 14
Failure code [CA451] Rail Press Sensor High Error................................................................ 18
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 20
Failure code [CA553] Rail Press High Error ............................................................................ 22
Failure code [CA554] Rail Press Sensor In Range Error ........................................................ 23
Failure code [CA559] Rail Press Low Error............................................................................. 24
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 30
Failure code [CA757] All Persistent Data Lost Error ............................................................... 31
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 32
Failure code [CA1228] EGR Valve Servo Error 1 .................................................................... 34
Failure code [CA1625] EGR Valve Servo Error 2 .................................................................... 35
Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 36
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 40
Failure code [CA2249] Rail Press Very Low Error................................................................... 41
Failure code [CA2271] EGR Valve Lift Sens High Error .......................................................... 42
Failure code [CA2272] EGR Valve Lift Sens Low Error........................................................... 44
Failure code [CA2351] EGR Valve Sol Current High Error...................................................... 46
Failure code [CA2352] EGR Valve Sol Current Low Error....................................................... 48
Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................. 50
Failure code [CA2556] Grid Htr Relay Volt High Error............................................................. 52
Failure code [D110KB] Battery Relay Drive Short Circuit ........................................................ 54
Failure code [D196KA] Service Return Relay Open Circuit .................................................... 56
Failure code [D196KB] Service Return Relay Short Circuit..................................................... 58
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 60
Failure code [DA80MA] Auto. Lub. Abnormal.......................................................................... 62
Failure code [DA2RMC] Pump Comm. Abnormality................................................................ 4
Failure code [DA2SKQ] Model Selection Abnormality............................................................. 6
Failure code [DAFRMC] Monitor Comm. Abnormality ............................................................. 8
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit............................................................ 10
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 12
Failure code [DHPBMA] R Pump Press Sensor Abnormality.................................................. 14
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 16
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................... 18
Failure code [DW43KA] Travel Speed Sol. Open Circuit......................................................... 20
Failure code [DW43KB] Travel Speed Sol. Short Circuit ......................................................... 22
Failure code [DW45KA] Swing Brake Sol. Open Circuit.......................................................... 24
Failure code [DW45KB] Swing Brake Sol. Short Circuit.......................................................... 28
Failure code [DW91KA] Travel Junction Sol. Open Circuit...................................................... 30
PC400, 450-7E0 7
Failure code [DW91KB] Travel Junction Sol. Short Circuit ...................................................... 32

Failure code [DWJ0KA] Merge-divider Sol. Open Circuit ........................................................ 34
Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit........................................................ 36
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit ....................................................... 38
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit........................................................ 40
Failure code [DXA0KA] PC-EPC Sol. Open Circuit ................................................................. 42
Failure code [DXA0KB] PC-EPC Sol. Short Circuit ................................................................. 44
Failure code [DXE0KA] LS-EPC Sol. Open Circuit.................................................................. 46
Failure code [DXE0KB] LS-EPC Sol. Short Circuit.................................................................. 48
Failure code [DXE4KA] Service Current EPC Open Circuit .................................................... 50
Failure code [DXE4KB] Service Current EPC Short Circuit..................................................... 51
Failure code [DY20KA] Wiper Working Abnormality................................................................ 52
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 54
Failure code [DY2CKB] Washer Drive Short Circuit ................................................................ 56
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit......................................................... 58
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ......................................................... 60
Troubleshooting of electrical system (E-mode)............................................................... SEN03604-01
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 Windshield 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 IN” normally ..................................................... 42
E-21 Monitoring function fails to display “arm OUT” normally ................................................. 44
E-22 Monitoring function fails to display “bucket CURL” normally........................................... 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) .................................... SEN03605-01
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
8 PC400, 450-7E0
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
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
Troubleshooting of engine (S-mode) .............................................................................. SEN03606-01
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
50 Disassembly and assembly

General information on disassembly and assembly ....................................................... SEN03608-03
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketches of special tools ......................................................................................................... 11
Engine and cooling system............................................................................................. SEN03609-02
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 ............................................................... 20
PC400, 450-7E0 9
Removal and installation of radiator assembly ........................................................................ 29

Removal and installation of hydraulic oil cooler assembly....................................................... 31
Removal and installation of aftercooler assembly ................................................................... 33
Removal and installation of engine and hydraulic oil pump assembly..................................... 34
Power train...................................................................................................................... SEN03610-02
Removal and installation of travel motor and 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 machinery assembly ..................................................... 12
Removal and installation of swing circle assembly .................................................................. 19
Undercarriage and frame .................................................................................................SEN03611-02
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............................................................................................................. SEN03612-02
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 .................................................... 23
Removal and installation of work equipment assembly ........................................................... 2
Removal and installation of operator’s cab.............................................................................. 2
Removal and installation of operator’s cab glass (stuck glass) ............................................... 5
Removal and installation of front window assembly ................................................................ 14
Electrical system ............................................................................................................. SEN03615-02
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
90 Diagrams and drawings

Hydraulic diagrams and drawings................................................................................... SEN03618-00
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings ................................................................................... SEN03617-01
Electrical circuit diagram.......................................................................................................... 3
Connector list and stereogram................................................................................................. 13
10 PC400, 450-7E0
PC400, 450-7E0 11
SEN03580-03
PC400, 450(LC)-7E0 Hydraulic excavator

Form No. SEN03580-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)
12
SEN03581-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
00 Index and foreword 1

Foreword and general information
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 1
Safety notice 1
(Rev. 2008/08)
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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
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, fork-
lift, service car, etc.
2 PC400, 450-7E0
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l 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
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
PC400, 450-7E0 3
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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing 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 form-
ing 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 allow-
able 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 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC400, 450-7E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
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 immedi-
ately in an emergency.
PC400, 450-7E0 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner 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 dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
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 recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit 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 dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (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.
6 PC400, 450-7E0
How to read the shop manual 1
q 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.
q Materials and specifications are subject to change without notice.
q 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.
1. 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 dis-
assembly 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 7
3. 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 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain 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, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 PC400, 450-7E0
Explanation of terms for maintenance standard 1

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

q 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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence 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.
Example:
Standard size Tolerance
–0.022
120
–0.126
a 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)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC400, 450-7E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance 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 allow-

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 PC400, 450-7E0
Handling of electric equipment and hydraulic component 1

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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC400, 450-7E0 11
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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), 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-cir-
cuited 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 sur-
face 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 com-
pressed 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 com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 PC400, 450-7E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC400, 450-7E0 13
2) 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 dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 break-
age, 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 stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected 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.
14 PC400, 450-7E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
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) horizon-
tally 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 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
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 con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 PC400, 450-7E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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 con-
nectors 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 discon-
necting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC400, 450-7E0 17
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 perfor-
mance 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 clean-
ing 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 equip-
ment, 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC400, 450-7E0 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor 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)
Disconnect connector (1) according to the fol-

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

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

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.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC400, 450-7E0 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) 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 har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
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)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC400, 450-7E0
How to read electric wire code 1

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 sym-
bols. 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 nomi-
nal 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 indi-
cated.)
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)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC400, 450-7E0 23
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 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 PC400, 450-7E0
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW 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 AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
PC400, 450-7E0 25
Precautions when carrying out operation 1

[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. Precautions when carrying out removal work

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

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

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a 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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. 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 speci-
fied 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
4) 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.
5) 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”.
28 PC400, 450-7E0
Method of disassembling and connecting push-pull type coupler 1

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.
k 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
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 hexag-
onal 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 discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 PC400, 450-7E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect 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 hexag-
PC400, 450-7E0 31
Standard tightening torque table 1

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 applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 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 mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. 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.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. 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 Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC400, 450-7E0 33
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. 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 Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 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
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 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 Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC400, 450-7E0 35
Conversion table 1
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 hori-
zontal 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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 PC400, 450-7E0
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC400, 450-7E0 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 PC400, 450-7E0
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC400, 450-7E0 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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 Fahren-
heit 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 Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC400, 450-7E0
PC400, 450-7E0 41
SEN03581-02

© 2008 KOMATSU
All Rights Reserved
42
SEN03583-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 6
Weight table .................................................................................................................................................. 12
Table of fuel, coolant and lubricants.............................................................................................................. 16
PC400, 450-7E0 1
SEN03583-00 01 Specification
Specification dimension drawings 1

Backhoe specification
Dimensions 1
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
J Max. ground clearance mm 555 550 555 550
J: Excluding height of grouser [37 mm]
Variable gauge specification
Item Unit PC400-7E0 PC400LC-7E0 PC450-7E0 PC450LC-7E0

C Overall width mm 3,490 3590 3,490 3,490
2 PC400, 450-7E0
01 Specification SEN03583-00
Working ranges 1
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 — — — —
Max. reach at ground
G mm 11,820 11,820 11,800 11,800
level
PC400, 450-7E0 3
Loading shovel specification
Dimensions 1
PC400-7E0 PC400-7E0 PC400LC-7E0 PC400LC-7E0

Item Unit
Variable guage Fixed guage Variable guage Fixed guage
C Overall width mm 3,490 3,340 3,590 3,440
4 PC400, 450-7E0
Working ranges 1
Working ranges
PC400-7E0 PC400-7E0 PC400LC-7E0 PC400LC-7E0
Working range Unit
Variable guage Fixed guage Variable guage Fixed guage
A Max. digging reach mm 8,660 8,660 8,660 8,660
Maximum reach at
B mm 8,375 8,375 8,375 8,375
ground level
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
Min. reach at ground
E mm 4,850 4,850 4,850 4,850
level
F Min. swing radius mm 4,535 4,535 4,535 4,535
PC400, 450-7E0 5
Specifications 1
PC400-7E0, PC400LC-7E0
PC400-7E0 PC400LC-7E0
Machine model Fixed gauge Variable Fixed gauge Variable
spec. gauge spec. spec. gauge spec.
Serial number 60001 and up
Bucket capacity m3 1.9 1.9

Weight of machine kg 41,200 42,200
Max. digging depth mm 7,820 7,820
Working ranges
Max. vertical wall depth mm 6,870 6,870

Max. digging reach mm 12,025 12,025
Max. reach at ground level mm 11,820 11,820
Max. digging height mm 10,915 10,915
Performance
Max. dumping height mm 7,565 7,565

Max. digging force kN {kg} 256.0 {26,100} 256.0 {26,100}
(using power max. function) kN {kg} (274.6 {28,000}) (274.6 {28,000})
Swing speed rpm 9.1 9.1
Swing max. slope angle deg. 20 20
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: 5.5 Lo: 3.0, Mi: 4.4, Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm2} 77.7{0.79} 79.9 {0.82} 73.9 {0.75} 65.3 {0.67}
Overall length mm 11,940 11,940 11,940 11,940
Overall width mm 3,340 3,490 3,440 3,590
(Track gauge when retracted) mm — 3,090 — 3,590
Overall width of track mm 3,490 3,490 3,590 3,590
(Track gauge when retracted) mm — 2,990 — 3,090
Overall height mm 3,635 3,635 3,635 3,635
Overall height to top of machine mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320 1,320 1,320

Min. ground clearance mm 685 685 685 685
Tail swing radius mm 3,645 3,645 3,645 3,645
Min. swing radius of work equipment mm 4,735 4,735 4,735 4,735
Height of work equipment mm 9,210 9,210 9,210 9,210
at min. swing radius
Length of track on ground mm 4,020 4,020 4,350 4,350
Track gauge mm 2,740 2,890 2,740 2,890
Height of machine cab mm 2,920 2,920 2,920 2,920
Width of standard shoe mm 600 600 700 700
6 PC400, 450-7E0
Machine model PC400-7E0 PC400LC-7E0
Model SAA6D125E-5
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
No. of cylinders – bore × stroke mm 6 – 125 × 150
Piston displacement l {cc} 11.045 {11,045}
Flywheel horsepower kW/rpm {HP/rpm} 257/1,900 {345/1,900}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 1,383/1,400 {141/1,400}

Max. speed at no load rpm 1,930
Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HPh} 203 {147}
Starting motor 24V, 7.5 kW
Alternator 24V, 35A
Battery 12V, 110 Ah × 2
Radiator core type Aluminum wave type, 4 rows
Carrier roller 2 on each side
Undercarriage
Track roller 7 on each side 8 on each side

Assembly-type triple grouser, Assembly-type triple grouser,
Track shoe
46 on each side 49 on each side
Type × No. HPV160+160 (190), variable displacement, piston type × 2

Control valve Hydraulic pump
Delivery l /min 345 × 2
Set pressure MPa {kg/cm2} 37.8 {380}
Type × No. 6-spool type + 1-spool type × 1
Control method Hydraulic
KMV200ADT-2, Variable displacement, piston type

Travel motor
Hydraulic motor
(with brake valve, parking brake): × 2

Hydraulic system
KMF230ABE-5, Fixed displacement piston type

Swing motor
(with safety valve, holding brake, reverse rotation preventive
valve): × 1
Boom (*1) Arm (*1), (*2) Bucket

Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston 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 Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
PC400, 450-7E0 7
PC450-7E0, PC450LC-7E0
PC450-7E0 PC450LC-7E0
Machine model Fixed gauge Variable gauge Fixed gauge Variable gauge
spec. spec. spec. spec.
Serial Number 30001 and up

Operating weight kg 42,700 44,000 43,700 44,600
Working ranges
Max. vertical wall depth mm 6,600 6,600

Performance

(using power max. function) (275.5 {28,300}) (275.5 {28,300})
Swing max. slope angle deg. 17 17
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: 5.5 Lo: 3.0, Mi: 4.4, Hi: 5.5
Ground pressure kPa {kg/cm2} 80.5 {0.82} 82.9 {0.85} 76.5 {0.78} 78.1 {0.80}
Overall width mm 3,340 3,490 3,340 3,490
Overall width when retracted mm — 3,090 — 3,140
Overall width of track mm 3,340 3,490 3,340 3,490
Overall width of track when mm — 2,990 — 2,990
retracted
Overall height to top of machine mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320 1,320 1,320

Track gauge mm 2,740 2,890 2,740 2,890
8 PC400, 450-7E0
Model SAA6D125E-5
Performance
Engine

Alternator 24 V, 35 A
Undercarriage

Track shoe
Type × No. HPV160+160 (190), ariable displacement, piston type × 2

Hydraulic motor Control valve Hydraulic pump

Travel motor
Hydraulic system

Swing motor
valve): × 1
Boom (*1) Arm (*1),(*2) Bucket
Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston

Inside diameter of cylinder mm 160 185 160
Outside diameter of piston rod mm 110 130 110
Stroke mm 1,570 1,985 1,270
Max. distance between pins mm 3,830 4,740 3,140
Min. distance between pins mm 2,260 2,755 1,870
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
PC400, 450-7E0 9
PC400, 400LC-7E0
PC400-7E0 PC400LC-7E0
Machine model Fixed gauge Variable gauge Fixed gauge Variable gauge
spec. spec. spec. spec.
Serial Number 60001 and up 60001 and up

Operating weight kg 43,100 44,300
Working ranges

Performance

(using power max. function)
Swing max. slope angle deg. 20.0 20.0
Travel speed km/h Lo: 3.0, Hi: 5.5 Lo: 3.0, Hi: 5.5
Ground pressure 80.5 {0.82} 66.7 {0.68}
kPa {kg/cm2}
[standard triple grouser shoe width] [600 mm] [700 mm]
Overall width mm 3,340 3,490 3,440 3,590
(when track gauge retracted) mm — 3,090 — 3,140
Overall width mm 3,340 3,490 3,440 3,590
(when track gauge retracted) mm — 2,990 — 3,090
Overall height to top of cab mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of counterweight mm 1,320 1,320 1,320 1,320

Track gauge mm 2,740 2,890 2,740 2,890
10 PC400, 450-7E0
Serial number 60001 and up 60001 and up
Model SAA6D125E-5
Performance
Engine

Alternator 24 V, 35 A
Undercarriage

Track shoe
Type × No. HPV190+190, Variable displacement, piston type × 2

Hydraulic motor Control valve Hydraulic pump

Travel motor
Hydraulic system

Swing motor
valve): × 1
Boom Arm Bucket Bottom dump
Double-acting Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston piston

Inside diameter of cylinder mm 160 185 135 130
Outside diameter of piston rod mm 110 120 95 90
Stroke mm 1,338 1,375 1,287 284
Max. distance between pins mm 3,837 3,615 3,322 1,091
Min. distance between pins mm 2,499 2,240 2,035 807
PC400, 450-7E0 11
Weight table 1
PC400-7E0, PC400LC-7E0
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Engine assembly 1,660 1,660

• Engine 1,314 1,314
• Damper 14.7 14.7
• Hydraulic pump 210 210
Radiator, oil cooler assembly 213 213

Hydraulic tank, filter assembly (excluding
198 198
hydraulic oil)
Fuel tank (excluding fuel) 251 251
Revolving frame 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
Center swivel joint 40 40
Fixed gauge Variable gauge Fixed gauge Variable gauge
specification specification specification 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
Unit: kg
Track shoe assembly

• Standard triple grouser shoe (600 mm) 4,470 4,760
• Standard triple grouser shoe (700 mm) 4,890 5,210
• Wide triple grouser shoe (800 mm) 5,320 5,670
• Wide triple grouser shoe (900 mm) — 6,130
Boom assembly 3,290 3,290
Arm assembly 1,374 1,374
Bucket assembly 1,366 1,366
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 510 510
Bucket cylinder assembly 297 297
Link assembly 258 258
Boom pin 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
PC400, 450-7E0 13
PC450-7E0, PC450LC-7E0
Unit: kg
Engine assembly 1,660 1,660

• Engine 1,314 1,314
• Damper 14.7 14.7
• Hydraulic pump 210 210
Radiator oil cooler assembly 213 213

Hydraulic tank, filter assembly
198 198
(excluding hydraulic oil)
Fuel tank (excluding fuel) 251 251
Revolving frame 3,402 3,402
Operator’s cab 279 279
Operator’s 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
Center swivel joint 40 40
Fixed gauge Variable gauge Fixed gauge Variable gauge
specification specification specification 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
Final drive (including travel motor) 722 × 2 722 × 2
14 PC400, 450-7E0
Unit: kg
Track shoe assembly

Standard triple grouser shoe (600 mm) 4,470 4,760
Standard triple grouser shoe (700 mm) 4,890 5,210
Wide triple grouser shoe (800 mm) — —
Boom assembly 3,380 3,380

Arm assembly 1,622 1,622
Bucket assembly 1,941 1,941
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 580 580
Bucket cylinder assembly 297 297
Link assembly 258 258
Boom pin 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
PC400, 450-7E0 15
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
16 PC400, 450-7E0
Unit: l
PC400/400LC-7E0, PC450/450LC-7E0
Reservoir
Specified (l) Refill (l)
Engine oil pan 42 38
Swing machinery case 20.0 20.0
Final drive case 12 12
Damper case 1.07 1.07
Hydraulic system 472 248
Fuel tank 650 —
Cooling system 36 —
a For the HO46-HM, use the oil recommended by Komatsu.
PC400, 450-7E0 17
SEN03583-00

© 2008 KOMATSU
All Rights Reserved
18
SEN03585-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine related parts ........................................................................................................................................ 2
Radiator, oil cooler and aftercooler ................................................................................................................. 3
PC400, 450-7E0 1
SEN03585-00 10 Structure, function and maintenance standard
Engine related parts 1
1. Damper assembly Outline

2. Drive plate A wet type damper assembly is used.
3. Torsion spring Oil capacity: 1.07 l
4. Stopper pin
5. Friction plate
6. Muffler
7. Rear engine mount
8. Front engine mount
2 PC400, 450-7E0
10 Structure, function and maintenance standard SEN03585-00
Radiator, oil cooler and aftercooler 1
1. Oil cooler 6. Net

2. Radiator 7. Shroud
3. Radiator cap 8. Radiator outlet hose
4. Radiator inlet hose 9. Aftercooler
5. Reservoir tank 10. Condenser
Specifications
Radiator: Aluminum wave type, 4 rows
Oil cooler: CF40-1
PC400, 450-7E0 3
SEN03585-00

© 2008KOMATSU
All Rights Reserved
4
SEN03586-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Power train
Power train...................................................................................................................................................... 2
Final drive ....................................................................................................................................................... 4
Sprocket .......................................................................................................................................................... 6
Swing machinery............................................................................................................................................. 8
Swing circle................................................................................................................................................... 10
PC400, 450-7E0 1
Power train 1
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
2 PC400, 450-7E0
PC400, 450-7E0 3
Final drive 1
1. Level plug 8. Cover

2. Drain plug 9. Ring gear (No. of teeth: 98)
3. No. 1 planetary gear (No. of teeth: 43) 10. Sprocket
4. No. 1 sun gear (No. of teeth: 10) 11. Floating seal
5. No. 2 sun gear (No. of teeth: 18) 12. Travel motor
6. No. 1 planetary carrier 13. No. 2 planetary gear (No. of teeth: 38)
7. No. 2 planetary carrier
Specifications
Reduction ratio:
– 10 + 98 × 18 + 98 = –68.600
10 18
4 PC400, 450-7E0
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear Standard clearance Clearance limit
14 and No. 1 planetary gear 0.15 – 0.54 1.10
Backlash between No. 1 planetary
15 gear and ring gear
0.18 – 0.66 1.30

16 carrier and motor
0.06 – 0.24 —
Replace
Backlash between No. 2 sun gear
17 and No. 2 planetary gear
0.15 – 0.51 1.00

0.17 – 0.60 1.20

19 carrier and No. 2 sun gear
0.15 – 0.54 —
20 Amount of wear on sprocket tooth Repair limit: 6

Standard size Repair limit Rebuild or replace
21 Width of sprocket tooth
90 87
PC400, 450-7E0 5
Sprocket 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip
355 343
Build-up welding
2 Thickness of tooth root 20.8 14.8
for rebuilding or
3 Width of tooth 90 87 replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth
4 Wear of tooth shape
shape)
6 PC400, 450-7E0
Full-size drawing of sprocket tooth shape
a 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 7
Swing machinery 1
1. Swing pinion (No. of teeth: 13) 8. Swing motor

2. Cover 9. Oil level gauge
3. Case 10. No. 1 planetary gear
4. No. 2 planetary gear 11. No. 1 planetary carrier
5. No. 2 sun gear 12. No. 2 planetary carrier
6. Ring gear 13. Drain plug
7. No. 1 sun gear
8 PC400, 450-7E0
1
Specifications
Reduction ratio:
19 + 68 × 16 + 68 = 24.039
19 16
Unit: mm
Backlash between swing motor Standard clearance Clearance limit
14 shaft and No. 1 sun gear 0.18 – 0.28 —
Backlash between No. 1 sun gear
0.15 – 0.51 1.00

0.17 – 0.60 1.10

17 carrier and No. 2 sun gear
0.40 – 0.75 1.20
Backlash between No. 2 sun gear Replace

0.16 – 0.55 1.00

0.17 – 0.60 1.10
Backlash between coupling and

20 swing pinion
0.08 – 0.25 —
Backlash between swing pinion and

21 swing circle
0.00 – 1.21 2.00
Clearance between plate and cou-

22 pling
0.57 – 1.09 —
Standard size Repair limit Apply hard

Wear of swing pinion surface con- chrome plating,
23 tacting with oil seal recondition, or
150 –0
–0.100
—
replace
PC400, 450-7E0 9
Swing circle 1
1. Swing circle inner race (No. of teeth: 84) Specifications

2. Ball Reduction ratio: –84/13 = –6.462
3. Swing circle outer race Amount of grease: 33 l (G2-LI)
a. Inner race soft zone "S" position

b. Outer race soft zone "S" position
Unit: mm
Axial clearance of bearing Standard clearance Repair limit
4 (when mounted on chassis)
Replace
0.5 – 1.6 3.2
10 PC400, 450-7E0
PC400, 450-7E0 11
SEN03586-00

© 2008 KOMATSU
All Rights Reserved
12
SEN03587-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Undercarriage and frame
Track frame and recoil spring.......................................................................................................................... 2
Idler ................................................................................................................................................................. 4
Carrier roller .................................................................................................................................................... 6
Track roller ...................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC400, 450-7E0 1
Track frame and recoil spring 1

a The following drawing indicates PC400-7E0 and PC450-7E0.
1. Idler q The dimensions and the number of track roll-

2. Track frame ers depend on the model, but the basic struc-
3. Carrier roller ture is not different.
4. Final drive q Number of track rollers
5. Track roller
Model Q'ty (one side)
6. Track shoe
7. Center guard PC400, 450-7E0 7
8. Front guard PC400LC-7E0,
8
PC450LC-7E0
2 PC400, 450-7E0
Standard shoe
Models
PC400-7E0 PC400LC-7E0 PC450-7E0 PC450LC-7E0
Item
Shoe width 600 mm 700 mm 600 mm 600 mm
Link pitch 228 mm 228 mm 228 mm 228 mm
No. of shoes (one side) 46 (Pieces) 49 (Pieces) 46 (Pieces) 49 (Pieces)
Unit: mm
Standard size Tolerance Rapair limit
Vertical width of idler Track +3

148 —
9 guide frame –1
Idler
145 ±0.5 — Rebuild or replace
support
Track +4
302 —
Horizontal width of idler frame –1
10 guide Idler
297 — —
support
Standard size Rapair limit
Free length × Installation Installation Installation
Free length
11 Recoil spring O.D. length load load Replace
239 kN
845.3 × 262 690 — —
{24,375 kg}
PC400, 450-7E0 3
Idler 1
4 PC400, 450-7E0
Unit: mm
1 Outside diameter of protrusion
704 —
2 Outside diameter of tread 660 648
3 Depth of tread 22 28 Rebuild or replace
4 Thickness of tread 21 15
5 Total width 202 —
6 Width of tread 48.5 54.5
Clearance between bushing and
7 support 0.46 – 0.86 —
(Sum of clearance at both sides)
Tolerance
Standard size Standard clearance
Clearance between shaft and Shaft Hole
8 bushing –0.120 +0.360 Replace bushing
95 0.340 – 0.567
–0.207 +0.220
Tolerance Standard
Standard size
Interference between idler and Shaft Hole interference
9 bushing
–0.062 +0.037
102.6 0.064 – 0.149
–0.027 +0.087
PC400, 450-7E0 5
Carrier roller 1
Unit: mm
1 Outside diameter of flange
179 —
3 Width of tread 50.3 —
4 Thickness of tread 32 25
5 Width of flange 19 —
Standard Tolerance Standard Clearance
Clearance between shaft and bush- size Shaft Hole clearance limit Replace
6 ing –0.250 +0.074 0.250 –
54 —
–0.280 +0.040 0.354
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
7 bushing +0.117 +0.030 0.057 –
61 —
+0.087 +0.040 0.117
Standard clearance Clearance limit
8 Axial clearance of roller
0.5 – 0.7 —
6 PC400, 450-7E0
Track roller 1
Unit: mm
1 Outside diameter of outer flange
240 —
Outside diameter of inner flange
2 (Double flange)
237 —

4 Thickness of tread 56.2 48 Build-up welding
5 Overal width 278 — for rebuilding or
replace
Single flange 54.6
6 Width of tread —
Double flange 51.6
Width of outer Single flange 32.6 —
7 flange Double flange 32.6 —
Width of inner frange
8 (Double frame)
23.0 —
9 Axial play 0.4 – 1.0 —

Clearance between shaft and size Shaft Hole clearance limit
10 bushing –0.250 +0.174
80 0.279 – 0.524 1.5 Replace bushing
–0.350 +0.029
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
11 bushing +0.108 –0.006
87.6 0.014 – 0.144 —
+0.008 –0.036
PC400, 450-7E0 7
Track shoe 1
a P portion shows the link of bushing press fitting end.
Unit: mm
1 Link pitch
228.9 231.9
Reverse or replace
Standard size Reverse
2 Outside diameter of bushing
71.5 66.5
3 Thickness of bushing metal 11.9 6.9 Adjust or replace
4 Link height
129 119
Repair or replace
Thickness of link metal (bushing
5 press-fitting portion)
34.5 24.5
8 PC400, 450-7E0
Unit: mm
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
Inside
9 width
106
Overall
10 Link
width
51.6 Repair or replace
Tread
11 width
44.8
12 Protrusion of pin 4.4

13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer —
17 Bushing 118 – 304 kN {12 – 31 ton}
Regular
18 pin
176 – 451 kN {18 – 46 ton}
Press-fitting force —
19 Master
137 – 284 kN {14 – 29 ton}
(*) pin
Tightening torque
Retightening angle (deg.)
a. Regu- (Nm {kgm})
lar link 393±39
Triple grouser shoe 120±10
20 Shoe bolt {40±4} Retighten
Tightening torque Lower limit torque
b. Master Retightening angle (deg.)
(Nm {kgm}) (Nm {kgm})
link
— — —
Tolerance Standard
Standard size
Interference between bushing and Shaft Hole interference
21 link +0.494 +0.074
71 0.380 – 0.494
+0.454 +0.074
Interference between regular pin +0.235 –0.218
22 and link
47
+0.085 –0.280
0.303 – 0.515
Tolerance
Clearance between regular pin and Shaft Hole
23 bushing +0.235 +0.915
47 0.180 – 0.830 Adjust or replace
+0.085 +0.415
Tolerance Standard interfer-
Standard size
24 Interference between master pin Shaft Hole ence
(*) and bushing +0.03 –0.218
47 0.218 – 0.310
+0.03 –0.280
Tolerance
25 Clearance between master pin and Shaft Hole
(*) bushing –0.2 +0.915
47 0.615 – 1.315
–0.4 +0.415
* Dry type track link
PC400, 450-7E0 9
Triple grouser shoe
Unit: mm
1 Height
37 22
2 Thickness 13
3 33
Length of base
4 27 Build-up welding
for rebuilding or
5 25.5 replace
6 Length at tip 17.5
7 23.5
8 Thickness
50 35
10 PC400, 450-7E0
PC400, 450-7E0 11
SEN03587-00

© 2008 KOMATSU
All Rights Reserved
12
SEN03588-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Hydraulic system, Part 1
Hydraulic equipment layout drawing ............................................................................................................... 2
Hydraulic tank and filter .................................................................................................................................. 4
Hydraulic pump ............................................................................................................................................... 6
PC400, 450-7E0 1
Hydraulic equipment layout drawing 1
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
2 PC400, 450-7E0
PC400, 450-7E0 3
Hydraulic tank and filter 1
1. Oil filler cap Specifications

2. Breather Tank capacity: 335 l
3. Hydraulic tank Amount of oil inside tank: 248 l
4. Sight gauge
5. Strainer Pressure valve
6. Filter element Relief cracking pressure:
7. Strainer 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
8. Bypass valve 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}
4 PC400, 450-7E0
PC400, 450-7E0 5
Hydraulic pump 1
Type: HPV160+160 (190)
6 PC400, 450-7E0
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. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
7. Variable volume valve
PC400, 450-7E0 7
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
8 PC400, 450-7E0
Function
q The pump converts the engine rotation trans-
mitted 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 q Piston (6) carries out relative movement in the
spline (14). axial direction inside each cylinder chamber of
q Shaft (1) is supported by front and rear bear- cylinder block (7).
ings (15). q Cylinder block (7) seals the pressurized oil to
q Tip of piston (6) is shaped as a concave ball valve plate (8) and carries out relative rotation.
and shoe (5) is caulked to it to form one unit. q This surface is designed so that the oil pres-
q Piston (6) and shoe (5) constitute the spherical sure balance is maintained at a suitable level.
bearing. q The oil inside each cylinder chamber of cylin-
q Rocker cam (4) has flat surface (A), and shoe der block (7) is suctioned and discharged
(5) is always pressed against this surface while through valve plate (8).
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 pres-
sure bearing when it slides.
PC400, 450-7E0 9
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q 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).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
10 PC400, 450-7E0
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 pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
PC400, 450-7E0 11
1. LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: LS mode selector pilot port 7. Plug
8. 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 con-
trol 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
Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is conducted to the larger
pressure (PLS) (LS pressure) from the outlet diameter end from the port (K).
port of the control valve brought to spring q The same pump pressure (PP) is conducted to
chamber (B), and main pump discharge pres- the smaller diameter end from the port (J).
sure (PP) brought to port (H) of sleeve (8). q According to the difference in the areas on
q Magnitude of the force resulting from this LS servo piston (12), the pressure moves in to the
pressure (PLS), force of spring (4) and the direction of minimizing the swash plate angle.
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q 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)
q Before the engine is started, servo piston (12) is
pushed to the left. (See the figure to the right.)
q 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)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
PC400, 450-7E0 13
2) Action for the direction of maximizing the pump delivery
q When the difference between the main pump q If the output pressure of the EPC valve for the
pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is
words, LS differential pressure (EPLS) generated on piston (7).
becomes smaller (for example, when the area q If piston (7) is pushed to the right, setting force
of opening of the control valve becomes larger of spring (4) is weakened, changing the LS dif-
and pump pressure PP drops), spool (6) is ferential pressure (EPLS) [Difference between
pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D)
pressure (PLS) and the force of spring (4). and (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q 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.)
q 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.
14 PC400, 450-7E0
3) Action for the direction of minimizing the pump delivery
q 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.
q 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.
q 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.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
PC400, 450-7E0 15
4) When servo piston is balanced
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted so that the bal-
the large diameter end of the piston as (A1), anced stop position of this spool (6) may be
the area receiving the pressure at the small determined when (PP) – (PLS) = 2.65 MPa {27
diameter end as (A0), and the pressure flowing kg/cm2} at the specified median.
into the large diameter end of the piston as q If (PSIG) [Output pressure of LS-EPC valve
(PEN). ranging from 0 to 2.9 MPa {0 to 30 kg/cm2}] is
q If the main pump pressure (PP) of the LS valve applied to port (G), the balanced stop position
and the combined force of spring (4) and LS changes in proportion to (PSIG) pressure in
pressure (PLS) are balanced, and the relation- the range of (PP) – (PLS) = 1.18 to 2.65 MPa
ship is (A0) × (PP) = (A1) × (PEN), servo pis- {12 to 27kg/cm2}.
ton (12) will stop in that position.
q 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 dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure 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.
16 PC400, 450-7E0
2. PC valve
PA: Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PM: Mode selector pressure pilot port 4. Spool
PPL: Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function q If the engine speed goes below the specified

q When the pump discharge pressure (PP1) value because of increased load, the controller
(self-pressure) and (PP2) (other pump pres- sends a command current to PC-EPC valve
sure) are high, the PC valve controls the pump solenoid in order to reduce the slope angle in
so that the volume of oil beyond the discharge proportion to reduction in the engine speed.
pressure-based specific flowrate may not be
conducted however you may increase the con-
trol valve stroke. Namely it is intended at con-
trolling 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 dis-
charge 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.
PC400, 450-7E0 17
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) a Other pump's pressure denotes the pressure
q Command current (X) is being sent to PC-EPC of the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump's
q This command current acts on PC-EPC valve pressure is that of the rear pump.
to output the signal pressure in order to modify And for the rear pump pressure, the other
the force pushing piston (2). pump's pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined 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 opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
18 PC400, 450-7E0
PC400, 450-7E0 19
Action of spring
q Load of springs (4) and (6) on the PC valve is q When pump pressures (PP1) and (PP2) are
determined by the swash plate position. small, spool (3) will be positioned in the left
q As servo piston (9) moves to right, spring (6) is side.
retracted. q Port (C) and (D) are connected, and the pres-
q If the servo piston moves further, it will be con- sure entering the LS valve becomes drain
tacted again seat (5) and spring (6) will be pressure (PT).
fixed. q If port (E) and port (G) of the LS valve are con-
q After that, spring (4) alone will operate. nected, the pressure entering the large diame-
q The spring load is changed by servo piston (9) ter end of the piston from port (J) becomes
as it extends or compresses springs (4) and drain pressure (PT), and servo piston (9)
(6). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Accompanied with move of servo piston (9),
q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the
affected by the command current (X) to PC- spring force becomes weaker.
EPC valve solenoid. q As the spring force is weakened, spool (3)
q Port (C) of the PC valve is connected to port moves to the right, the connecting between
(E) of the LS valve. port (C) and port (D) is shut off and the pump
q Self pressure (PP1) enters port (B) and the discharge pressure ports (B) and (C) are con-
small diameter end of servo piston (9), and nected.
other pump pressure (PP2) enters port (A).
20 PC400, 450-7E0
q 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.
q Servo piston (9) stop position (= Pump deliv-
ery) is decided by the position where the push-
ing force generated from the pressures (PP1)
and (PP2) applied to spool (3), the pushing
force of the solenoid in PC-EPC valve gener-
ates and the pushing force of springs (4) and
(6) are balanced.
PC400, 450-7E0 21
(2) When the load on actuator is large and pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end this flow, to make the pump delivery the minimum.
level of this pressure becomes approximately q When servo piston (9) moves to the right,
half of the main pump pressure (PP2). 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 pis-
ton (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.
22 PC400, 450-7E0
q 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.
q The relationship between the average pump
pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q 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.
q 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 aver-
age 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
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 If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the discharge amount
q In this case, the power is directly supplied from larger.
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure 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.
q 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.
24 PC400, 450-7E0
(2) When the main pump is under heavy load
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on In the same way as in above, the command drive switch is ON is situated further to the left (B)
current (X) sent to PC-EPC valve solenoid (1) than when the pump controller is normal (A).
becomes constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q 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.
q 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.
q 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 corre-
sponding to the current sent to the PC-EPC
valve solenoid through the resistor.
PC400, 450-7E0 25
3. LS(PC)-EPC valve
C : To LS (PC) valve
P : From self pressure reducing valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
26 PC400, 450-7E0
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. 1) When signal current is 0
q When it receives signal current (i) from the (coil is de-energized)
controller, it generates the EPC output pres- q When there is no signal current flowing from
sure in proportion to the size of the signal, and the controller to coil (2), coil (2) is de-energized.
outputs it to the LS (PC) valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).
PC400, 450-7E0 27
2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and LS
shut off from port (C). (PC) valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be balance with pressure of
port (C) + spring load of spring (4).
q The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in propor-
tion to the size of the signal current.
28 PC400, 450-7E0
4. Variable volume valve
C: To PC valve 1. Plug
P: From self pressure reducing valve 2. Block
T: To tank 3. Piston
4. Spring
Function
q The variable volume valve stabilizes the EPC
valve's output pressure.
Operation
q 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.
PC400, 450-7E0 29
SEN03588-00

© 2008 KOMATSU
All Rights Reserved
30
SEN03589-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 1
Control valve 1
Outline
q The control valve consists of a 7-spool valve (6-
spool 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 con-
nected to each other inside the assembly, the
assembly is compact and easy to maintain.
q With one spool provided for one work equip-
ment, this control valve is simple in construc-
tion.
A1: To bucket cylinder bottom PLS1: To front pump control
A2: To L.H. travel motor PLS2: To rear pump control
A3: To boom cylinder bottom PP1: From front pump
A4: To swing motor PP2: From rear pump
A5: To R.H. travel motor PP1S: Pressure sensor mounting port
A6: To arm cylinder head PP2S: Pressure sensor mounting port
A-1: To boom cylinder bottom PPS1: To front pump control
A-2: To attachment 1 PPS2: To rear pump control
A-3: To attachment 2 PR: To solenoid valve, PPC valve, and EPC valve
B1: To bucket cylinder head PS: From merge-divide solenoid valve
B2: To L.H. travel motor PST: From travel junction valve solenoid valve
B3: To boom cylinder head PX1: From 2-stage relief solenoid valve
B4: To swing motor PX2: From 2-stage relief solenoid valve
B5: To R.H. travel motor T: To tank
B6: To arm cylinder bottom T1: To tank
B-1: To arm cylinder bottom TS: To tank
B-2: To attachment 1 TSW: To swing motor S-port (suction side)
B-3: To attachment 2
BP1: Boom raising PPC output pressure 1. 6-spool valve
BP5: From 2-stage safety valve solenoid valve 2. Cover A
BP6: From attachment select solenoid valve 3. Cover B
P1: From bucket PPC and EPC valves 4. Boom Hi and arm Hi valve
P2: From bucket PPC and EPC valves 5. Service valve 1
P3: From L.H. travel PPC valve 6. Service valve 2
P4: From L.H. travel PPC valve 7. Merge-divider valve
P5: From boom PPC and EPC valves 8. Boom drift preventive valve
P6: From boom PPC and EPC valves 9. Quick return valve
P7: From swing PPC and EPC valves 10. Boom Hi valve check valve
P8: 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
2 PC400, 450-7E0
General view
PC400, 450-7E0 3
Sectional view
(1/5)
4 PC400, 450-7E0
1. Pressure compensation valve (Arm OUT)

2. Pressure compensation valve (R.H. travel
REVERSE)
3. Pressure compensation valve (LEFT swing)
4. Pressure compensation valve (Boom RAISE)
5. Pressure compensation valve (L.H. travel
REVERSE)
6. Pressure compensation valve (Bucket DUMP)
7. Pressure compensation valve (Boom Hi
RAISE)
8. Variable pressure compensation valve (Ser-
vice 1)
vice 2)
10. Pressure compensation valve (Arm Hi IN)
11. Pressure compensation valve (Bucket CURL)
FORWARD)
13. Pressure compensation valve (Boom LOWER)
14. Pressure compensation valve (RIGHT swing)
FORWARD)
16. Pressure compensation valve (Arm IN)
17. Main relief valve
18. Unload valve
19. Unload valve
21. Spool (Service 2)
23. Spool (Boom Hi)
24. Spool (Bucket)
25. Spool (L.H. travel)
26. Spool (Boom)
27. Spool (Swing)
28. Spool (R.H. travel)
29. Spool (Arm)
30. Spool (Arm Hi)
Unit: mm

Free length × Installed Installed Installed
Free length
31 Spool return spring Outside diameter length load load
417 N 333 N
54.2 × 34.8 51.2
{42.5 kg}
— {34.0 kg}
393 N 315 N If damaged or
32 Spool return spring 54.5 × 34.8 51.2
{40.1 kg}
— {32.1 kg} deformed, replace
421 N 336 N spring.
{42.9 kg}
— {34.3 kg}
251 N 201 N
{25.6 kg}
— {20.5 kg}
417 N 333 N
{42.5 kg}
— {34.0 kg}
PC400, 450-7E0 5
(2/5)
6 PC400, 450-7E0
1. Suction safety valve (Arm OUT)

2. Suction valve (Right travel REVERSE)
3. Suction valve (Boom RAISE)
4. Suction valve (Left travel REVERSE)
5. Suction valve (Boom Hi RAISE)
6. Suction safety valve (Service 1)
8. 2-stage suction safety valve (Service 1)
9. Suction safety valve (Arm Hi IN)
10. Suction safety valve (Bucket CURL)
11. Suction valve (Left travel FORWARD)
12. 2-stage suction safety valve (Boom LOWER)
13. Suction valve (Right travel FORWARD)
14. Suction safety valve (Arm IN)
15. LS shuttle valve (Arm)
16. LS shuttle valve (Right travel)
17. LS select valve
18. LS shuttle valve (Boom)
19. LS shuttle valve (Left travel)
20. LS shuttle valve (Bucket)
21. LS shuttle valve (Service 1)
23. LS check valve
24. Pressure relief plug
Unit: mm

Free length
25 Suction valve spring Outside diameter length load load If damaged or
5.5 N 4.4 N deformed, replace
46.8 × 7.5 40.6
{0.56 kg}
— {0.45 kg} spring.
1.5 N 1.2 N
26 Check valve spring 11.5 × 4.6 8.5
{0.15 kg}
— {0.12 kg}
PC400, 450-7E0 7
(3/5)
8 PC400, 450-7E0
1. Unload valve
2. Safety valve (Boom RAISE)
4. 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

Free length
22 Spool return spring Outside diameter length load load If damaged or
50.0 × 14.4 42.0
{2.0 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
PC400, 450-7E0 9
(4/5)
10 PC400, 450-7E0
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divide valve (Main)
6. 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

Free length
157 N 126 N
46.6 × 21.8 33.0
{16.0 kg}
— {12.8 kg}
250 N 200 N
{25.5 kg}
— {20.4 kg}
{18.1 kg}
35.3 N 28.2 N spring.
{3.6 kg}
— {2.88 kg}
13.7 N 11.0 N
{1.4 kg}
— {1.12 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7 × 20.5 23.0
{5.1 kg}
— {4.08 kg}
PC400, 450-7E0 11
(5/5)
12 PC400, 450-7E0
Boom Hi and arm Hi valve
1. Boom Hi check valve

2. Quick return valve
4. Arm Hi spool
6. Boom Hi spool
RAISE)
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

20. LS bypass plug
PC400, 450-7E0 13
A1: To bucket cylinder bottom 1. 6-spool valve

A2: To L.H. travel motor 2. Cover A
A3: To boom cylinder bottom 3. Cover B
A4: To swing motor 4. Boom Hi and arm Hi valve
A5: To R.H. travel motor 5. Service valve 1
A6: To arm cylinder head 6. Bottom dump valve
A-1: To boom cylinder bottom 7. Merge-divider valve
A-2: To attachment 1 8. Boom drift preventive valve
A-3: To bottom dump cylinder head 9. Quick return valve
B1: To bucket cylinder head 10. Boom Hi valve check valve
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
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
P1: From bucket PPC and EPC valves
P2: From bucket PPC and EPC valves
P3: From L.H. travel PPC valve
P4: From L.H. travel PPC valve
P5: From boom PPC and EPC valves
P6: From boom PPC and EPC valves
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
PP1S: Pressure sensor mounting port
PP2S: 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
PX2: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: To swing motor S-port (suction side)
14 PC400, 450-7E0
General view
PC400, 450-7E0 15
Sectional view
(1/5)
16 PC400, 450-7E0
1. Pressure compensation valve (Arm OUT)

REVERSE)
3. Pressure compensation valve (LEFT swing)
4. Pressure compensation valve (Boom RAISE)
REVERSE)
6. Pressure compensation valve (Bucket DUMP)
RAISE)
vice 1)
9. Compensation valve (Bottom dump)
11. Pressure compensation valve (Bucket CURL)
FORWARD)
13. Pressure compensation valve (Boom LOWER)
14. Pressure compensation valve (RIGHT swing)
FORWARD)
16. Pressure compensation valve (Arm IN)
18. Unload valve
19. Unload valve
21. Spool (Bottom dump)
23. Spool (Boom Hi)
24. Spool (Bucket)
25. Spool (L.H. travel)
26. Spool (Boom)
27. Spool (Swing)
28. Spool (R.H. travel)
29. Spool (Arm)
30. Spool (Arm Hi)
Unit: mm

Free length
417 N 333 N
54.2 × 34.8 51.2
{42.5 kg}
— {34.0 kg}
{40.1 kg}
421 N 336 N spring.
{42.9 kg}
— {34.3 kg}
251 N 201 N
{25.6 kg}
— {20.5 kg}
417 N 333 N
{42.5 kg}
— {34.0 kg}
PC400, 450-7E0 17
(2/5)
18 PC400, 450-7E0
1. Suction safety valve (Arm OUT)

2. Suction valve (Right travel REVERSE)
3. Suction valve (Boom RAISE)
4. Suction valve (Left travel REVERSE)
7. Suction safety valve (Bottom dump)
8. 2-stage suction safety valve (Service 1)
10. Suction safety valve (Bucket CURL)
11. Suction valve (Left travel FORWARD)
12. 2-stage suction safety valve (Boom LOWER)
13. Suction valve (Right travel FORWARD)
14. Suction safety valve (Arm IN)
15. LS shuttle valve (Arm)
16. LS shuttle valve (Right travel)
17. LS select valve
18. LS shuttle valve (Boom)
19. LS shuttle valve (Left travel)
20. LS shuttle valve (Bucket)
22. LS shuttle valve (Bottom dump)
23. LS check valve
24. Pressure relief plug
Unit: mm

Free length
25 Suction valve spring Outside diameter length load load If damaged or
46.8 × 7.5 40.6
{0.56 kg}
1.5 N 1.2 N
{0.15 kg}
— {0.12 kg}
PC400, 450-7E0 19
(3/5)
20 PC400, 450-7E0
1. Unload valve
2. Safety valve (Boom RAISE)
4. 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

Free length
22 Spool return spring Outside diameter length load load If damaged or
50.0 × 14.4 42.0
{2.0 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
PC400, 450-7E0 21
(4/5)
22 PC400, 450-7E0
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divide valve (Main)
6. 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

Free length
157 N 126 N
46.6 × 21.8 33.0
{16.0 kg}
— {12.8 kg}
250 N 200 N
{25.5 kg}
— {20.4 kg}
{18.1 kg}
35.3 N 28.2 N spring.
{3.6 kg}
— {2.88 kg}
13.7 N 11.0 N
{1.4 kg}
— {1.12 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7 × 20.5 23.0
{5.1 kg}
— {4.08 kg}
PC400, 450-7E0 23
(5/5)
24 PC400, 450-7E0
Boom Hi and arm Hi valve

2. Quick return valve
4. Arm Hi spool
6. Boom Hi spool
RAISE)
Service valve 1
9. LS shuttle valve
11. Spool
Bottom dump valve

16. Spool
18. Unload valve

20. LS bypass plug
PC400, 450-7E0 25
CLSS 1
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity pis-
tem, which has the following characteristics: ton pumps, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
26 PC400, 450-7E0
Basic principle
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate angle shifts toward the
is controlled so that LS differential pressure maximum position if LS differential pressure
(EPLS) (the difference between pump pres- (EPLS) is lower than the set pressure of the
sure PP and control valve outlet port LS pres- LS valve (when the actuator load pressure is
sure PLS) (load pressure of actuator) is high). If it becomes higher than the set pres-
constant. sure (when the actuator load pressure is low),
q [LS differential pressure (EPLS) = Pump dis- the pump swash plate angle shifts toward the
charge pressure (PP) – LS pressure (PLS)] minimum position.
q If it becomes higher than the set pressure
(when the actuator load pressure is low), the
pump swash plate angle shifts toward the mini-
mum position.
LS differential pressure ( E PLS) and pump

swash plate angle
a For details of functions, see the “Hydraulic

pump”.
PC400, 450-7E0 27
2. Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to bal-
ance the load.
q 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 (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.
28 PC400, 450-7E0
3. System diagram
a The illustration shows actuator (7) in the merge

mode with stroke end at the time of relief.
1. Front pump 9. LS circuit

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
PC400, 450-7E0 29
Functions and operation by valve 1

Hydraulic circuit diagram and the name of valves
30 PC400, 450-7E0
1. Arm valve 42. 2-stage suction safety valve

2. R.H. travel valve Set pressure: 1 stage: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
3. Swing valve 2 stage: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
4. Boom valve 43. Safety valve
5. L.H. travel valve Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
6. Bucket valve
7. Boom Hi valve
8. Arm Hi valve
9. Service valve 1
10. Service valve 2
11. Arm spool
12. R.H. travel spool
13. Swing spool
14. Boom spool
15. L.H. travel spool
16. Bucket spool
17. Boom Hi spool
18. Arm Hi spool
19. Service spool 1
20. Service spool 2
22. Variable pressure compensation valve
23. Suction valve
24. Check valve (for boom regeneration circuit)
25. Check valve (for arm regeneration circuit)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
35. 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)
36. Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
37. Unload valve (bucket side)
Cracking pressure: 3.1 MPa {32 kg/cm2}
38. Unload valve (arm side)
Set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
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 31
32 PC400, 450-7E0
1. Arm valve 42. 2-stage suction safety valve

2. R.H. travel valve Set pressure: 1 stage: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
3. Swing valve 2 stage: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
4. Boom valve 43. Safety valve
5. L.H. travel valve Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
6. Bucket valve 44. Suction safety valve
7. Boom Hi valve Set pressure: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
8. Arm Hi valve 45. Suction safety valve
9. Service valve 1 Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
10. Bottom dump valve 46. Suction safety valve
11. Arm spool Set pressure: 31.9 ± 0.5 MPa {325 ± 5 kg/cm2}
12. R.H. travel spool
13. Swing spool
14. Boom spool
16. Bucket spool
17. Boom Hi spool
18. Arm Hi spool
19. Service spool 1
20. Bottom dump spool
22. Variable pressure compensation valve
23. Suction valve
24. Check valve (for boom regeneration circuit)
25. Check valve (for arm regeneration circuit)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
35. Main relief valve (bucket side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
36. Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
37. Unload valve (bucket side)
38. Unload valve (arm side)
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 33
Unload valve
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function Operation
q Drains an oil discharge for the portion of the q Pressure of pump circuit (3) is received by the
minimum pump swash plate angle while all end of valve (2).
control valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
load of spring (5) inside the valve (this pres- q Pressurized oil of pump circuit (3) stops at
sure will be P1). valve (2), and the pressure rises as no relief is
q Since LS pressure is drained from the LS available.
bypass valve, LS pressure C tank pressure C q When this pressure becomes larger than the
0 MPa {0 kg/cm2}. 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 cir-
cuit pressure during unloading is larger than
the pump LS control pressure, the signal is
output to minimize the pump swash plate
angle.
34 PC400, 450-7E0
q During operation (a work within a scope of dis- 2. Operation of relief valve

charge by a minimum swash plate angle), the q When the cylinder reaches the stroke end, the
discharge pressure for the portion of minimum main relief valve opens.
pump swash plate angle is set to LS pressure q The pump delivery (Q) is relieved to the
+ P1 pressure. tank.(See the system diagram)
q LS control differential pressure (EPLS) of dis- q The pump discharge pressure (PP) and LS
charge for the portion of minimum swash plate pressure (PLS) become approximately the
angle will be equal to P1 pressure. same as each has not flow at the upstream
and downstream of the spool, and LS differen-
tial pressure (EPLS) becomes 0 kg/cm2.
q 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.
q Mechanically, operation of PC valve have the
prevalence to that of LS valve.
q The pump is held at a minimum swash plate
angle by the cut-off function of PC valve.
PC400, 450-7E0 35
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. 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
q 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.
36 PC400, 450-7E0
LS bypass valve
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass valve
6. 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 pres-
sure.
q Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the cir-
cuit 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
Pressure compensation valve

1. During independent operation and under maximum load pressure
(If the load pressure is higher than other work equipment during a combined operation)
1. Hydraulic pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function q As principle, port (C) and spring chamber (E)

q Pressure compensation valve works as the are not interconnected in an integrated pres-
load check valve. sure compensation valve.
q If the pump pressure (LS pressure) is lower q If high peak pressure is generated at port (C),
than the load at port (c), shuttle valve (3) in valve (7) does not collide with the valve cham-
pressure compensation valve piston (4) inter- ber.
connects spring chamber (E) and port (C). q With a bucket valve, etc., port (C) and spring
q The force of spring (5) operates piston (4) and chamber (E) are designed to interconnect
valve (2) to the closing direction. before valve (7) is seated.
Integrated pressure compensation valve

q High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator cir-
cuit or repetitive peak pressure occurs continu-
ously (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.
38 PC400, 450-7E0
2. 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 meter-
in 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 pres-
sure 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
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 down-
stream 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
Pressure compensation valve inner shuttle valve

1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. 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 sepa-
rated.
PC400, 450-7E0 41
2. In the case of travel
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensa-
tion valve without shuttle valve (3) is adopted.
42 PC400, 450-7E0
Boom regeneration circuit

1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1. Hydraulic pump
2. Boom spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q Provides the regeneration circuit from the cyl- q If the cylinder head pressure is lower than the
inder bottom to the cylinder head when the bottom pressure, pressurized oil (A) from the
boom is lowered and increases flow to the cyl- cylinder bottom flows to drain circuit (B) from
inder bottom. the notch of boom spool (2).
q On the other hand, remaining oil flows to regen-
eration 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).
PC400, 450-7E0 43
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
44 PC400, 450-7E0
Arm regeneration circuit

1. If the cylinder head pressure is higher than the bottom pressure
1. Hydraulic pump
2. Arm spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q During arm digging, regeneration circuit pro- q If the cylinder head pressure is higher than the
vided from the cylinder head to the bottom bottom pressure, pressurized oil (A) from the
increases the cylinder speed as the cylinder cylinder head flows to drain circuit (B) from the
flow involves the pump delivery plus regener- notch of arm spool (2).
ated flow. 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).
PC400, 450-7E0 45
2. If the cylinder head pressure is lower than the bottom pressure
Function
q Check valve (6) provided to regeneration cir-
cuit (C) closes to shut off the flow from the cyl-
inder bottom to the head.
46 PC400, 450-7E0
Merge-divider valve 1
1. When flows from the pumps merge [if pilot pressure (PS) is OFF]
1. Main spool 5. LS circuit (bucket side)

2. Spring 6. LS circuit (bucket side)
3. LS spool 7. LS circuit (arm side)
4. Spring 8. LS circuit (arm side)
Function Operation
q Merges pressurized oil (P1) and (P2) dis- q Since pilot pressure (PS) is OFF, output pres-
charged from the two pumps or divides (to sure from PPC valve is 0 MPa {0 kg/cm2}.
respective control valve group). q Main spool (1) is pressed to the right by spring
q Merges and divides LS circuit pressure. (2) and ports (E) and (F) are interconnected.
q Merges pressurized oil (P1) and (P2) dis-
charged 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 intercon-
nected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and
(8) to all the pressure compensation valves.
PC400, 450-7E0 47
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
q Pilot pressure (PS) turns ON, and output pres-
sure 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 out-
put pressure from the PPC valve, intercon-
nects 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
LS select valve
Function Operation
q Prevents high LS pressure from the swinging 1. If pilot pressure (BP) is OFF
from entering the LS circuit of work valves q Since pilot pressure (BP) is OFF, piston (3) is
while the swinging and work equipment are in pressed to the left by spring (2).
combined operation. q When swing-operated, swing LS pressure (P1)
q Prevents high pressure generated during enters port (A) after passing swing spool (5).
swing drive and improves operability of work q Valve (1) is pressed to the left and ports (A)
equipment. and (B) are interconnected.
q Swing LS pressure (P1) flows to LS shuttle
valve (8).
2. If pilot pressure (BP) is ON

q If pilot pressure (BP) is ON, BP pressure con-
tracts spring (2), and piston (3) shifts to the
right.
q Valve (1) is pressed to the right and intercon-
nection between ports (A) and (B) is closed.
q Swing LS pressure (P1) stops flowing to LS
shuttle valve (8).
q If swing LS pressure (P1) rises, other LS cir-
cuits are not affected.
a The illustration shows the state of simulta-

neous operation of swinging and R.H. travel.
[(BP) pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
PC400, 450-7E0 49
Self pressure reducing valve
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. During neutral and when load pressure (P2) 3. When load pressure (P2) is high
is low q Load pressure (A2) increases with the opera-
a When load pressure (A2) is lower than self tion of digging, etc, and the pump discharge
pressure reducing valve output pressure (PR) increases accordingly.
q Pressure (P2) increases to [(Ød area × P2
q Valve (7) is pressed to the closing direction of pressure) = force of spring (8) + (Ød area × PR
circuit between ports (P2) and (A2) by spring pressure)], and valve (7) moves to the right to
(8) and under pressure (PR) (which is 0 MPa the stroke end.
{0 kg/cm2}). q As a result, opening between ports (P2) and
q When pressurized oil flows in from port (P2), a (A2) increases, and the pass resistance
balance is reached due to [(Ød area × P2 pres- reduces, reducing the engine horsepower loss.
sure) = force of spring (8) + (Ød area × PR q When pressure (PR) rises above the set pres-
pressure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure q Pressurized oil flows from port (PR) to orifice
(P2) at a constant level over pressure (PR). (a) in spool (14), then flows to seal drain port
q When pressure (PR) rises above the set pres- (TS) from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and
q Pressurized oil flows from port (PR) to orifice after orifice (a) in spool (14) and then spool
(a) in spool (14), then flows to seal drain port (14) moves to close the pass between ports
(TS) from poppet (11) opening. (P2) and (PR).
q Differential pressure is generated before and q Pressure (P2) is reduced by the opening at this
after orifice (a) in spool (14) and then spool time and adjusted to a constant pressure (the
(14) moves to close the pass between ports set pressure) and supplied as pressure (PR).
(P2) and (PR).
q 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 51
4. When abnormally high pressure is gener-

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

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

1. When travel lever is in neutral
Function Operation
q Regulates flow to each cylinder by controlling q The oil in stroke regulation signal chamber (a)
the stroke of each spool of the boom, arm, and is drained through orifices (5) and (6) of pis-
bucket using the pilot pressure of travel PPC tons (3) and (4) in the travel spring case and
valve while climbing a steep grade, raising the the travel PPC valve.
boom, digging with arm, dumping, bucket-dig- q When operated for boom raising (or arm dig-
ging or operating dump. ging, dumping, bucket digging, dumping),
q When controlling the stroke of the boom, arm spool (1) moves to the left until it makes con-
and/or bucket, pilot pressure of travel PPC tact with the end face of spring casing (2) (st0).
valve passes through the circuit inside the con-
trol valves to actuate the system.
PC400, 450-7E0 55
2. When traveling
Operation
q If the right travel lever is set in the reverse (or q When operated for boom raising (or arm in,
forward) direction, pilot pressure from the PPC out, bucket curl, dump), spool (1) moves to the
valve presses spool (7) to the left (or right). left.
q Spool (7) pushes piston (3) to close orifice (5) q Maximum stroke of the spool is limited to (st1)
and shut off stroke regulation signal chamber for the amount of movement (st2) of piston (8)
(a) and the drain circuit of the travel PPC to the right.
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 PC400, 450-7E0
Boom drift preventive valve

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)[= Ø(d1) area – Ø(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
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).
holding pressure of the boom cylinder bottom
are shut off.
58 PC400, 450-7E0
3. 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 pop-
pet is drained through orifice (c).
q Pressurized oil of the boom bottom flows to ori-
fice (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
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 ring-
shaped area (S) [= Ø(d1) area – Ø(d2) area]
caused by the difference between the outside
diameter (d1) of poppet (5) and the seat diam-
eter (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. 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).
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).
holding pressure of the arm cylinder head are
shut off.
PC400, 450-7E0 61
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 pop-
pet 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
q If abnormally high pressure is generated in the q If arm drift preventive valve (If equipped) is
boom cylinder bottom circuit, the pressurized installed to the arm cylinder head circuit, the
oil in port (B) pushes check valve (6) open, boom cylinder bottom circuit pressure force or
then safety valve (3) operates. arm cylinder head circuit pressure force,
whichever having higher pressurized oil,
pushes check valve (6) or (6A) open to actuate
safety valve (3).
PC400, 450-7E0 63
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 q Or (Ød2 pressure receiving force > Ød1 pres-
pushed by the pilot spool from the PPC valve. sure receiving force + spring force)
q Pressurized oil in chamber (b) inside the valve q Valve (2) is pressed to the left and pressurized
is drained through orifice (c). oil is led from port (A) to (B).
q Pressurized oil of the arm bottom side flows to q From port (B), pressurized oil is drained
orifice (a) o chamber (b) o orifice (c) o drain directly to the tank.
(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 [Ød2 area (S2)
(seat diameter area)] on the side of port (A)
increases by the sum of the pressure receiving
force of pressure receiving portion[Ød1 area
(S1)] on the chamber (b) side of valve (2) and
the spring force.
64 PC400, 450-7E0
2. 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
Lift check valve

Function 2. While engine is running
q This valve applies back pressure to the drain q Output pressure (PR) of the self pressure
circuit to prevent generation of negative pres- reducing valve is conducted to through the
sure on each actuator (motors, cylinders, etc.). control valve to spring chamber (c) of lift check
valve (3).
Operation q Output pressure (PR) applied to spring cham-
1. While engine is stopped ber (c) is applied to the left end of valve (1)
q Pressurized oil is not fed to the self pressure (area of Ød) to push valve (1) to the right.
reducing valve from the pump, and valve (1) is q At this time, pressure (PA) of drain circuit (a) of
pressed to the right by the force of spring (2). the control valve is applied to the right end of
q Drain circuit (a) of the control valve is con- valve (1) (area of Ød1) to push valve (1) to the
nected with port (T) through orifice (b) of valve left.
(1). q Valve (1) strikes balance to make the back
pressure equal to (PA) in the equation below.
(Area of Ød) × PR + force of spring (2)

PA =
Area of Ød1
66 PC400, 450-7E0
Main relief valve
1. Spring
2. 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
q 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 com-
pletes the setting of the 2nd stage.
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
2-stage suction safety valve

[Installed to port (B) on the boom cylinder head side and port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function Operation
q Enables to provide the safety valve set pres- q The safety set pressure is determined by
sure in two stages, and make the low-pressure spring (1) installed load.
setting smaller.
q Enables to relieve a load without lever opera- 1. If pilot pressure is OFF (high-pressure set-
tion if high load is applied to the cylinder. ting)
q Improves work efficiency and reduces machine q Since pilot pressure (P) is OFF, piston (2) is
body vibration. pressed to the left by spring (3). [Spring (1)
installed load < spring (3) installed load]
q Spring (1) installed load becomes maximum
and the set pressure rises.
q Passage (B) is interconnected to the drain cir-
cuit via passage (C) and chamber (D).
68 PC400, 450-7E0
2. If pilot pressure is ON (low-pressure setting)

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

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

valve spool) q Regulates flow distribution to the service valve
B. Cylinder port when the service valve (attachment) and the
C. Load pressure of other work equipment work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area
1. Valve ratio variable)
2. Spring q Pressurized oil from the service valve spool is
3. Sleeve applied to the left side of valve (1) and is led to
4. Poppet chamber (g) via orifice (a).
5. Spring q LS pressure is led to chamber (e) through ori-
6. Screw fice (d).
7. Locknut q Pressurized oil of cylinder port is led to cham-
8. Cap ber (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).
70 PC400, 450-7E0
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 equip- pressure (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).
forces applying to valve (1) may be expressed q Differential pressure is generated between the
with the following equation: upstream and downstream of orifice (a), which
reduces the pressure force in chamber (g).
P × A1 = P × A2 + LS(A2 – 1) + F q Force that presses valve (1) to the left is
reduced.
A1: Area of Ød1 q A state is reached where the area ratio has
A2: Area of Ød2 become smaller.
F: Force of spring q Valve (1) moves to the right, and the flow
P: Pump discharge oil pressure increases from the pump to the cylinder.
PC400, 450-7E0 71
Attachment circuit selector valve 1
ACC: To accumulator 1. Spool

ATT: To attachment 2. Spring
P1: From attachment selector solenoid valve
T: To hydraulic oil tank
TS: To hydraulic oil tank
V: To control valve
Unit: mm

Free length × Installed Installed Installed If damaged or
Free length
3 Spool return spring Outside diameter length load load deformed, replace
834 N 667 N spring.
132 × 29 114.5
{85.0 kg}
— {68.0 kg}
72 PC400, 450-7E0
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 2. When breaker is installed
installed q Pilot pressure (P1) from the attachment circuit
q Spool (1) is pressed to the left by the force of selector solenoid valve compresses spring (2),
spring (2). moving spool (1) rightward to the stroke end.
q Ports (ATT) and (V) are interconnected and q Ports (ATT) and (V) are shut off and ports
ports (ATT) and (T) are shut off. Attachment is (ATT) and (T) are interconnected.
thus interconnected to the control valve. q Pressurized oil returning from the breaker
returns directly to the hydraulic tank via port (T)
without passing through the control valve.
PC400, 450-7E0 73
Holding valve 1
(For the boom and arm)
74 PC400, 450-7E0
CY: To work equipment cylinder

PCY: For pressure pickup port and equalizer circuit
PI: From PPC valve
T: To tank
V: From control valve
1. Pilot spool
2. Spool (1st stage spool)
3. Spring (2nd stage spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm

Free length
7 Check valve spring Outside diameter length load load
12.7 N 10.2 N
20.8 × 12.2 13.5
{1.3 kg}
— {1.04 kg} If damaged or
{6.0 kg}
78.5 N 62.8 N
{8.0 kg} — {6.4 kg}
126 N 100 N
{12.8 kg}
— {10.2 kg}
PC400, 450-7E0 75
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 If the piping is bursted

q Check valve (5) is closed under the holding q If piping (A) is broken between the control
pressure of the cylinder led from port (CY) to valve and the work equipment cylinder, cham-
chamber (b). bers (a) and (b) are shut off in the same way as
q At the neutral, pilot pressure led to port (PI) the piping is free from damages.
from the PPC valve is 0 MPa {0 kg/cm2}. q Pressure for the work equipment cylinder is
q Spool (1) is pressed to the left by the force of held to prevent a sudden drop of the work
springs (2) and (3) equipment.
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 differ-
ence in leakage.
76 PC400, 450-7E0
2. 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 com-
bined 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 the piping is bursted

q If piping (A) between the control valve and the
work equipment cylinder is broken, pressur-
ized 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.
PC400, 450-7E0 77
3. When returning pressurized oil to the main

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

q Holding pressure of the work equipment cylin- q If piping (A) bursts between the control valve
der is led to chamber (b) and check valve (5) and the work equipment cylinder.
closes. q Pressurized oil in chamber (a) flows out to the
q Pilot pressure from the PPC valve is led to port bursted portion but resupplied from chamber
(PI) and reaches [Pilot Pressure > Force of (b).
Spring (3)] (area of d). q Since pressurized oil flows via opening (c) of
q Spool (1) moves to the right to the standby spool (1), a sudden drop of the cylinder is pre-
position. (1st stage stroke) vented.
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 cham-
bers (a) and (b) are interconnected. (2nd stage
stroke)
q Pressurized oil returns to the control valve
from the work equipment cylinder.
78 PC400, 450-7E0
PC400, 450-7E0 79
SEN03589-00

© 2008 KOMATSU
All Rights Reserved
80
SEN03590-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 1
Valve control 1
1. Travel PPC valve B. Boom (RAISE)

2. Service PPC valve C. Boom (LOWER)
3. Service pedal D. Bucket (DUMP)
4. L.H. travel lever E. Bucket (CURL)
5. R.H travel lever F. Hold
6. R.H. PPC valve G. Arm (IN)
7. R.H. work equipment control lever H. Arm (OUT)
8. Solenoid valve J. Swing (RIGHT)
9. Accumulator K. Swing (LEFT)
10. Control valve L. Neutral
11. Hydraulic pump M. Travel (REVERSE)
12. Junction box N. Travel (FORWARD)
13. L.H. work equipment control lever
14. L.H. PPC valve
Lever positions
A. Hold
2 PC400, 450-7E0
PC400, 450-7E0 3
PPC valve 1
Work equipment and swing PPC valve
P: From self pressure reducing valve

P1: L.H. PPC: Arm out/R.H. PPC: Boom lower
P2: L.H. PPC: Arm in/R.H. PPC: Boom raise
P3: L.H. PPC: Swing left/R.H. PPC: Bucket curl
P4: L.H. PPC: Swing right/R.H. PPC: Bucket dump
T: To tank
4 PC400, 450-7E0
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever connection)
Unit: mm
Centering spring Free length
12 (for ports P3 and P4) Outside diameter length load load
17.7 N 13.7 N If damaged or
42.5 × 15.5 34.0 —
{1.80 kg} {1.40 kg} deformed, replace
Centering spring 29.4 N 23.5 N spring.
13 (for ports P1 and P2) 44.5 × 15.5 34.0
{3.0 kg}
—
{2.40 kg}
16.7 N 13.7 N
14 Metering spring 26.5 × 8.15 24.9
{1.70 kg}
—
{1.40 kg}
PC400, 450-7E0 5
Operation q The relationship of the position of spool (1) and

1. When in neutral body (10) [fine control hole (f) is in the middle
q Ports (A) and (B) of the control valve and ports between drain chamber (D) and pump pres-
(P1) and (P2) of the PPC valve are connected sure chamber (PP)] does not change until
to drain chamber (D) via fine control hole (f) in retainer (9) contacts spool (1).
spool (1). q Metering spring (2) contracts in proportion to
the stroke of the control lever.
q Pressure at port (P1) also rises in proportion to
q 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.
2. During fine control

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

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Fine control hole (f) is shut off from drain
and the pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the self
ized oil at port (P1) is released. pressure reducing valve passes through fine
q If the pressure of port (P1) is lowered exces- control hole (f) and flows to chamber (A) from
sively, spool (1) is pushed down by metering port (P1) to push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q 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 cham-
ber with pressurized oil.
PC400, 450-7E0 7
Travel PPC valve
P: From main pump

P1: L.H. reverse
P2: L.H. forward
P3: R.H. reverse
P4: R.H. forward
P5: Travel signal
P6: Steering signal
T: To tank
8 PC400, 450-7E0
PC400, 450-7E0 9
10 PC400, 450-7E0
1. Plate
2. Body
3. Piston
4. Collar
5. Centering spring
6. Metering spring
7. Valve
8. Dumper
9. Steering signal spool
10. Steering signal spool spring
Unit: mm
Free length
11 Centering spring Outside diameter length load load
108 N 86.3 N If damaged or
48.6 × 15.5 32.5 —
16.7 N 13.7 N spring.
{1.7 kg}
—
{1.4 kg}
8.8 N 7.1 N
13 Steering signal spring 12.8 × 7.3 8.5
{0.9 kg}
—
{0.72 kg}
PC400, 450-7E0 11
1. Pressure reducing valve q The relationship of the position of spool (1) and
body (10) [fine control hole (f) is in the middle
Operation between drain chamber (D) and pump pres-
1) When in neutral sure chamber (PP)] does not change until
q Ports (A) and (B) of the control valve and ports retainer (9) contacts spool (1).
(P1) and (P2) of the PPC valve are connected q Metering spring (2) contracts in proportion to
to drain chamber (D) via fine control hole (f) in the stroke of the control lever.
spool (1). q Pressure at port (P1) also rises in proportion to
q 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.
2) During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol 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).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
12 PC400, 450-7E0
3) During fine control q Therefore, the pilot pressure oil from the self
(When control lever is returned) pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from
is pushed up by the force of centering spring port (P1) to push the control valve spool.
(3) and pressure at port (P1). q The oil returning from chamber (B) passes
q Because of this, fine control hole (f) is con- from port (P2) through fine control hole (f') and
nected to drain chamber (D), and the pressur- flows to drain chamber (D).
ized oil at port (P1) is released.
q If the pressure of port (P1) is lowered exces-
sively, spool (1) is pushed down by metering
spring (2).
q Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q 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 cham-
ber with pressurized oil.
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 pres-
sure 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
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
t 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 steer-
ing signal.
q Any signal is not output from port (P6) while
the machine is travelling straight (forward or
4) At full stroke reverse) or in neutral.
q Lever (5) pushes down piston (4), and retainer
q Accordingly, whether the machine is being
(9) pushes down spool (1).
steered is judged by the signal of port (P6).
q Fine control hole (f) is shut off from drain
chamber (D), and is interconnected to pump
pressure chamber (PP).
PC400, 450-7E0 13
Operation
1) When in neutral
q No output is made from respective output ports

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

output] and R.H. motor forward [port (P4) out-
put], pressure of both left spring chamber (k)
and right spring chamber (l) rises high.
q Steering signal spool (j) remains at neutral
position and does not output a steering signal
to port (P6).
PC400, 450-7E0 15
3) When steered or pivot-turned
a The Illustration shows the circuit for left forward (slow) and right forward (fast) operation.
q If the operation quantities of both levers are dif- q Port (P4) pressure of the L.H. or R.H. PPC
ferent from each other as in the steering opera- valves, whichever having a higher output pres-
tion (if the difference of the pilot pressure sure, is output to port (P6) as the steering sig-
between both sides is higher than a certain nal.
level), the pilot pressure is output as the steer-
ing signal.
q The pressure in left spring chamber (k) of
steering signal spool (j) is (P2).
q The pressure in right spring chamber (l) is
(P4).
q When the pressure state reaches [(P4 – P2) ×
(Spool section) > Spring set load], the spool is
switched to the direction of the arrow.
16 PC400, 450-7E0
4) When counter-rotated
a The illustration shows the circuit for travelling left reverse and right forward.
q When operating L.H. motor reverse [port (P1)

output] and R.H. motor forward [port (P4) out-
put], pressure of the right spring chamber (l)
only rises high.
q Steering signal spool (j) strokes to the left to
output the steering signal to port (P6).
PC400, 450-7E0 17
Service PPC valve
a For the details of operation, see the paragraph of “Work equipment swing PPC valve.“
18 PC400, 450-7E0
P: From self pressure reducing valve 1. Spool

P1: To service valve 2. Piston
P2: To service valve 3. Lever
T: To tank 4. Plate
5. Retainer
6. Body
Unit: mm
Free length
7 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 × 15.3 28.4 —
{12.7 kg} {10.2 kg} spring.
16.7 N 13.3 N
{1.70 kg}
—
{1.36 kg}
PC400, 450-7E0 19
Solenoid valve 1
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up and travel junc-
tion solenoid valves
1. PPC lock solenoid valve T: To tank

2. Travel junction solenoid valve A1: To PPC valve
3. Merge-divider solenoid valve A2: To main valve (Travel junction valve)
4. Travel speed solenoid valve A3: To main valve (Merge-divider valve)
5. Swing brake solenoid valve A4: To both travel motors
6. Machine push-up solenoid valve A5: To swing motor
7. 2-stage relief solenoid valve 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
20 PC400, 450-7E0
1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring
Operation
When solenoid is de-energized When solenoid is energized
q Since the signal current does not flow from the q The signal current flows from the controller to
controller, solenoid (3) is de-energized. For this solenoid (3), and the latter is energized.
reason, spool (4) is pushed to the left by spring Accordingly, spool (4) is pressed against to the
(6). By this operation, the pass from port (P) to right side. By this operation, the pressurized oil
port (A) is closed and the pressurized oil from from the main pump flows through port (P) and
the main pump does not flow into the actuator. spool (4) to port (A), then flows into the actua-
At this time, the oil from the actuator is drained tor. At the same time, port (T) closes and stops
through ports (A) and (T) into the tank. the oil from flowing to the tank.
PC400, 450-7E0 21
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
22 PC400, 450-7E0
Return oil filter 1
For breaker
1. Drain plug Specifications

2. Filter
Rated pressure: 6.9 MPa {70 kg/cm2}
3. Case
Flow: 200 l/min
4. Head cover
Relief valve cracking pressure:
5. Relief valve
0.34 ± 0.05 MPa {3.5 ± 0.5 kg/cm2}
Filter mesh size: 6 µm
Filtering area: 4,570 cm2
PC400, 450-7E0 23
Center swivel joint 1
1. Cover A1: To L.H. travel motor port PB

2. Body A2: From control valve port A2
3. Slipper seal B1: To L.H. travel motor port PA
4. O-ring B2: From control valve port B2
5. Shaft C1: To R.H. travel motor port PA
C2: From control valve port A5
D1: To R.H. travel motor port PB
D2: From control valve port B5
E: To L.H. and R.H. travel motors port P
T1: From L.H. and R.H. travel motors port T
T2: To tank
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 shaft Replace
80 — —
24 PC400, 450-7E0
Travel motor 1
Type: KMV200ADT-2
PA: From control valve Specifications

PB: From control valve Type : KMV200ADT-2
PI: From travel speed solenoid valve Theoretical displacement
T: To tank (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}
PC400, 450-7E0 25
26 PC400, 450-7E0
1. Output shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. End cover
7. Slow return valve
8. Regulator piston
9. Plate
10. Disk
11. Check valve spring
12. Check valve
13. Counter balance valve spool
14. Spool return spring
15. Safety valve
16. Regulator valve
17. Spring
18. Brake spring
19. Brake piston
20. Check valve
Unit: mm
Free length
62.5 × 32.0 42.0 —
3.04 N 2.45 N spring.
{0.31 kg}
—
{0.25 kg}
98.1 N 78.5 N
23 Regulator piston spring 55.0 × 9.0 50.0
{10.0 kg}
—
{8.0 kg}
PC400, 450-7E0 27
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot

pressurized oil from the self pressure reducing
valve does not flow to port (P).
q Regulator valve (16) is being pushed down by
spring (17).
q Pressurized oil conducted to end cover (6) by
pressing check valve (20) is then conducted to
chamber (b) via regulator valve (16).
q Force is generated on regulator piston (8) that
works in downward direction.
q 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.
28 PC400, 450-7E0
2) At high speed (motor swash plate angle at minimum)
q As the solenoid valve is energized, the pilot

pressurized oil from the self pressure reducing
valve flows to port (P).
q Regulator valve (16) is pushed upward.
q Pressurized oil in chamber (b) is drained to the
case and oil is conducted to chamber (a)
through regulator valve (16).
q Force is generated on regulator piston (8) that
works in upward direction.
q 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.
PC400, 450-7E0 29
Operation of parking brake

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

from the pump activates counterbalance valve
spool (13), opening the parking brake circuit.
q The pressurized oil is conducted to chamber
(e) of brake piston (19) and compresses spring
(18), pushing piston (19) toward right.
q Since the pushing force to plate (9) and disc
(10) disappears, plate (9) is separated from
disc (10) and the brake is released.
30 PC400, 450-7E0
2) When travel is stopped
q As the travel lever is placed in neutral, counter- q As brake piston (19) returns, flow of pressur-
balance valve spool (13) returns to the neutral ized oil is reduced with slow return valve (7).
position and closing the parking brake circuit. q The time delay will be set to activate the brake
q Pressurized oil in chamber (e) of brake piston only after the machine has stopped.
(19) keeps flowing through the orifice of slow
return valve (7) until counter balance valve
spool (13) is returned to the neutral.
q 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).
q Brake piston (19) is pushed to the left by spring
(18).
q Plate (9) and disc (10) are pushed together,
and the brake is applied.
PC400, 450-7E0 31
Brake valve Operation when pressurized oil is supplied

q The brake valve consists of check valves (1), q Operating the travel lever conducts the pres-
counterbalance valve (2) and safety valve (3). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil push-opens check valve
nents shall conform to the following. (12A) and then flows to motor outlet port (MB)
via motor inlet port (MA).
1. Counterbalance valve and check valve q The motor outlet side is closed by check valve
(12B) and spool (13), so the pressure at the
Function supply side rises.
q 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).
32 PC400, 450-7E0
Operation of brake during travelling downhill

q The pressurized oil on the supply side flows to q If indication of the machine runaway is sensed
chamber (S1) via orifice (E1) and orifice (E2) of while travelling downhill, the motor will be
the spool (13). caused to rotate without load to decrease the
q As the pressure in chamber (S1) goes above inlet side oil pressure.
the spool selector pressure, spool (13) is q Pressure in chamber (S1) is released through
pushed toward right. orifices (E1) and (E2).
q Port (MB) and port (PB) are connected, open- q As the pressure in chamber (S1) goes below
ing the motor outlet port side and starting the the spool selector pressure, spool (13) is
motor rotating. returned to the left by spring (14) and outlet
port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure 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.
PC400, 450-7E0 33
2. Safety valve
(bidirectional 2-stage set safety valve)
Function
q As long as the machine travel is stopped (or it q As the pressure goes above the set pressure,
is travelling downhill), the counterbalance [Difference in areas of circles (D1) and (D2) ×
valve closes the inlet and outlet circuits of the Pressure] compresses spring (2).
motor. q Poppet (1) is moved leftward and the pressur-
q Since the motor is rotated by inertial force, ized oil flows into chamber (MA) of the oppo-
pressure in the motor outlet port side is abnor- site circuit.
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
1) When pressure in chamber (MB) has
become high (when rotating clockwise)
q As long as the machine travel is stopped (or it
is travelling downhill), the check valve of coun-
terbalance 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 Operation of mechanism for varying set pres-
become high (when rotating counterclock- sure
wise) 1) When starting travel (high-pressure setting)
q As long as the machine travel is stopped (or it q As the travel lever is operated, the pressurized
is travelling downhill), the check valve of coun- oil from the pump moves spool (19) toward
terbalance valve closes chamber (MA) of the right.
outlet port circuit. q Above opens the pilot circuit to the safety
q The motor tries to continue rotation resorting to valve, conducting the pressurized oil to cham-
inertial force, thus pressure on the outlet port ber (J) through chamber (G) and passage (H).
(MA) is increased. 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.
q As the pressure goes above the set pressure,

[Difference in areas of circles (D1) and (D3) ×
Pressure] compresses spring (2).
q Poppet (1) is moved leftward and the pressur-
ized oil flows into chamber (MB) of the oppo-
site circuit.
PC400, 450-7E0 35
2) When travel is stopped (low-pressure set-

ting)
q When the travel lever is placed in neutral, the
pressure in chamber (PA) drops and spool (24)
returns to the neutral position.
q 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).
q Piston (3) moves to the left side, decreasing
the set load.
q 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 1
Type: KMF230ABE-5
B: From swing holding brake solenoid valve Specifications

MA: From control valve Type : KMF230ABE-5
MB: From control valve Theoretical displacement : 229.4 cm3/rev
S: From control valve Safety valve set pressure : 27.9 MPa {285 kg/cm2}
T: To tank Rated speed : 1,413 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}
1. Reverse prevention valve
2. Safety valve
PC400, 450-7E0 37
38 PC400, 450-7E0
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Check valve spring
16. Shuttle valve
17. Shuttle valve spring
Unit: mm
Basic dimensions Repair limit
Free length
18 Check valve spring Outside diameter length load load If damaged or
66.5 × 25.6 45.0 — spring.
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
19 Shuttle valve spring 24.5 × 11.6 14.5
{0.76 kg}
—
{0.61 kg}
PC400, 450-7E0 39
Swing holding brake

1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing holding brake is de-energized, q As the swing brake solenoid valve is ener-
the pressurized oil from the self pressure gized, the valve is switched.
reducing valve is shut off. q The pressurized oil from the self pressure
q Port (B) is connected to tank circuit (T). reducing valve is conducted brake chamber (a)
q Brake piston (7) is pushed down by brake via port (B).
spring (1). q After entering chamber (a), the pressurized oil
q Disc (5) and plate (6) are pushed together, and compresses brake spring (1) and pushes
the brake is applied. brake piston (7) up.
q Disc (5) is separated from plate (6), releasing
the brake.
40 PC400, 450-7E0
Relief valve portion 2. When swing is stopped

q When the swing control lever is returned to
Outline neutral, the supply of pressurized oil from the
pump to port (MA) is stopped.
q The relief valve portion consists of check
q The pressurized oil from the motor outlet can't
valves (2) and (3), shuttle valves (4) and (5),
return to the tank since the returning circuit to
and relief valve (1).
the tank is closed from control valve (6). Thus,
pressure on port (MB) increases.
Function
q Rotation resistance is generated on the motor
q When the machine is in the swing holding and hence the brake starts working.
mode, control valve (6) closes the motor outlet q Shuttle valve (4) is pressed as pressure on
circuit, but the motor rotation is continued by port (MB) goes above port (MA).
inertial force. q The pressure on chamber (C) is increased to
q The motor output, therefore, is abnormally the set pres sure of relief valve (1) and
increased, resulting in damaging the motor. becomes the same as that of port (MB).
q In order to prevent the motor damages, the q A high braking torque works on the motor,
relief valve relieves the abnormally high pres- thereby stopping the motor.
sure to port (S) from the motor outlet side q When relief valve (1) is being actuated, the
(high-pressure side) of the motor. relieved pressurized oil and the pressurized oil
from port (S) are fed to port (MA) through
Operation check valve (3).
1. When starting swing q Above prevents cavitation on port (MA).
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 con-
trol valve (6) and returns to the tank.
PC400, 450-7E0 41
Reverse prevention valve
42 PC400, 450-7E0
MA: From control valve

MB: From control valve
T1: To tank
T2: To tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
PC400, 450-7E0 43
Function 2. When motor is stopped temporarily

q This valve reduces the swing back generation q The motor rotation is reversed by the closing
in the swing body by the inertia of the swing pressure generated at port (MB). (1st time:
body, the backlash and rigidity of the machin- reverse rotation)
ery system, and the compression of the q Reversing pressure is generated on port (MA).
hydraulic oil when the swing is stopped. Pressure (MA) is conducted to chamber (a).
q The valve contributes in preventing collapsing q The pressure compresses spring (3) by use of
of load when the swing is stopped and also the difference in areas of circles (φD3 > φD4) of
contributes in reducing cycle time (enhances spool (2) and moves spool (2) to the right side.
the positioning performance, enabling you to q Port (MA) o chamber (b) will be intercon-
proceed to the next work quicker than ever). nected.
q Then ports (b) and (f) will be interconnected
Operation through the drilled hole (h) on spool (5). This
1. When port (MB) brake pressure is gener- interconnection bypasses the reversing pres-
ated sure on port (MA) to port (T), thereby prevent-
q Pressure (MB) is conducted to chamber (d) via ing the reverse rotation of the 2nd time.
notch (g).
q The pressure compresses spring (6) by use of
the difference in areas of circles (φD1 > φD2) of
spool (5) and moves spool (5) to the left side.
q Port (MB) o chamber (e) will be intercon-
nected.
q Since pressure (MA) is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.
44 PC400, 450-7E0
PC400, 450-7E0 45
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
46 PC400, 450-7E0
Unit: mm
Cylinder
size Shaft Hole clearance limit
–0.036 +0.261 0.083 –
Boom 110 0.412
Clearance between –0.090 +0.047 0.351
1 piston rod and bushing
Replace bushing
–0.036 +0.263 0.084 –
Arm 120 0.412
–0.090 +0.048 0.353
–0.036 +0.257 0.083 –
Bucket 110 0.447
–0.090 +0.047 0.347
–0.036 +0.169 0.136 –
Boom 110 —
–0.090 +0.100 0.259
Clearance between
–0.036 +0.169 0.136 –
2 piston rod support pin Arm 110
–0.090 +0.100 0.259
—
and bushing
–0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277 Replace pin or
–0.036 +0.190 0.106 – bushing
Boom 100 —
–0.090 +0.070 0.280
Clearance between
–0.036 +0.195 0.135 –
3 cylinder bottom support Arm 110
–0.090 +0.099 0.285
—
pin and bushing
–0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277
PC400, 450-7E0 47
Boom cylinder
Arm cylinder
Bucket cylinder
48 PC400, 450-7E0
Bottom dump cylinder
Unit: mm
Cylinder
size Shaft Hole clearance limit
–0.036 +0.261 0.083 –
Boom 100 0.415
–0.090 +0.047 0.351
Clearance between –0.036 +0.263 0.084 –
1 piston rod and bushing Arm 120 0.453 Replace bushing
–0.090 +0.048 0.353
–0.036 +0.222 0.083 –
Bucket 95 0.412
–0.090 +0.047 0.312
–0.036 +0.257 0.084 –
Bottom dump 90 0.447
–0.090 +0.048 0.347
–0.036 +0.457 0.136 –
Boom 110 1.0
–0.090 +0.370 0.259
–0.036 +0.457 0.406 –
Clearance between Arm 110 1.0
–0.090 +0.370 0.547
2 piston rod support pin
and bushing –0.036 +0.457 0.406 –
Bucket 100 1.0
–0.090 +0.370 0.547
–0.036 +0.457 0.406 –
Bottom dump 80 1.0
–0.090 +0.370 0.547 Replace pin or
–0.036 +0.161 0.110 – bushing
Boom 100 1.0
–0.090 +0.074 0.251
–0.036 +0.457 0.496 –
Clearance between Arm 110 1.0
–0.090 +0.370 0.547
3 cylinder bottom support
pin and bushing –0.036 +0.457 0.496 –
Bucket 80 1.0
–0.090 +0.370 0.547
–0.036 +0.457 0.406 –
Bottom dump 80 1.0
–0.090 +0.370 0.547
PC400, 450-7E0 49
SEN03590-00

© 2008 KOMATSU
All Rights Reserved
50
SEN03591-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 6
PC400, 450-7E0 1
Work equipment 1
2 PC400, 450-7E0
Unit: mm
Clearance between connecting pin size clearance limit
Shaft Hole
1 and bushing of revolving frame
and boom –0.036 +0.173
120 0.137 – 0.263 1.0
–0.090 +0.101
Clearance between connecting pin –0.036 +0.180
2 and bushing of boom and arm 120
–0.090 +0.112
0.148 – 0.270 1.0

3 and bushing of arm and link 100
–0.090 +0.081
0.117 – 0.262 1.0 Replace

4 and bushing of arm and bucket 100
–0.090 +0.077
0.113 – 0.228 1.0

5 and bushing of link and bucket 100
–0.090 +0.081
0.117 – 0.262 1.0

6 and bushing of link and link 100
–0.090 +0.097
0.133 – 0.280 1.0
7 Bucket clearance (a) 0.5 – 1.0

Adjust shims
8 Bucket clearance (b) 2.0
PC400, 450-7E0 3
4 PC400, 450-7E0
Unit: mm
Clearance between connecting pin size clearance limit
Shaft Hole
1 and bushing of revolving frame
and boom –0.036 +0.351
120 0.306 – 0.344 1.0
–0.090 +0.270
2 and bushing of boom and arm 120
–0.090 +0.283
0.306 – 0.470 1.0
Clearance between connecting pin –0.036 +0.352 Replace

3 and bushing of arm and bucket 100
–0.090 +0.283
0.319 – 0.442 1.0
Clearance between connecting pin

–0.036 +0.338
4 and bushing of bucket cylinder 100
–0.090 +0.284
0.320 – 0.428 1.0
and bucket
Clearance between connecting pin
–0.036 +0.344
5 and bushing of front bucket and 95
–0.090 +0.272
0.308 – 0.434 1.0
rear bucket
PC400, 450-7E0 5
Dimensions of components 1
1. Dimension of arm
6 PC400, 450-7E0
Unit: mm
PC400-7E0 PC450-7E0
No. Measuring position Standard Tolerance Standard Tolerance
size Shaft Hole size Shaft Hole
–0.036 +0.1 –0.036 +0.1
1 — φ110 φ110
–0.090 0 –0.090 0
+1.5 +1.5
Arm side 129.3 129.3
2 0 0
Cylinder head side 126 ±1.2 126 ±1.2
+0.5 +0.5
Boom side 355 355
0 0
3
–0.3 –0.3
Arm side 351 351
–0.8 –0.8
–0.036 +1.0 –0.036 +0.1
4 — φ120 φ120
–0.090 0 –0.090 0
5 — 514.8 — 570.6 —
6 — 195 — 208.2 —
7 — 1,038 — 1,132.2 —
8 — 3,375 — 3,375 —
9 — 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 —
–0.036 +0.1 –0.036 +0.1
15 — φ100 φ100
–0.090 0 –0.090 0
+1 +1
Bucket side 371 371
0 0
16
Link side 370 ± 0.5 370 ±0.5
–0.036 +0.1 –0.036 +0.1

17 — φ100 φ100
–0.090 0 –0.090 0
0 0
Arm itself 355 355
18 –0.5 –0.5
When press fitting bushing 370 — 370 —
Min. 1,870 — 1,870 —
19
Max. 3,140 — 3,140 —
PC400, 450-7E0 7
2. Dimension of bucket
8 PC400, 450-7E0
Unit: mm
PC400-7E0 PC450-7E0
No. Measuring position
Standard size Tolerance Standard size Tolerance
1 — 534.1 ±0.5 534.1 ±0.5
2 — 56.3 ±0.5 56.3 ±0.5
3 — 96°1' — 94°14' —
4 — 537.1 — 537.1 —
5 — 1,839 — 1,806 —
6 — 190 — 198 —
7 — — — — —
8 — 62°1' — 46°1' —
+0.1 +0.1
A — φ140.1 φ140.1
0 0
+0.063 +0.063
9 B — φ130 φ130
+0.054 +0.054
+0.1 +0.1
C — φ100 φ100
0 0
+1 +1
10 — 371
+0
371
+0
A — 57 — 58 —
11
B — 72 — 72 —
12 — 144 — 144 —
+0.5 +0.5
13 — 562.5
–2.5
562.5
–2.5
14 — φ26 — φ26 —
A — φ165 — φ165 —
15
B — — — — —
16 — φ230 — φ230 —
17 — 146.1 — 135.5 —
18 — 137.6 — 142 —
19 — R115 — R115 —
20 — R85 — R85 —
21 — 410 ±1 410 ±1
22 — 64 — 64 —
PC400, 450-7E0 9
SEN03591-00

© 2008 KOMATSU
All Rights Reserved
10
SEN03592-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Cab and its attachments
Air conditioner piping ...................................................................................................................................... 2
PC400, 450-7E0 1
Air conditioner piping 1
1. Receiver tank A: Fresh air

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

© 2008 KOMATSU
All Rights Reserved
4
SEN03593-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Electrical system
Engine control ................................................................................................................................................. 2
Electronic control system ...............................................................................................................................11
Monitor system.............................................................................................................................................. 36
Sensor........................................................................................................................................................... 54
KOMTRAX system........................................................................................................................................ 57
PC400, 450-7E0 1
Engine control 1
Operation of system
Starting engine Stopping engine
q When the starting switch is turned to the q When detecting that the starting switch is set to
“START” position, the starting signal flows to the “STOP” position, the engine controller cuts
the starting motor. Then, the starting motor the fuel injection to stop the engine.
turns to start 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 cor-
responding to the rotation angle to the engine
controller.
q The pump controller receives the fuel dial posi-
tion 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 injec-
tion quantity based on the instruction received
from the pump controller.
2 PC400, 450-7E0
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. 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 resis-
tance 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 3
Engine controller
q Meanings of signal classes in the terminal CN-CE01

table shown below are as follows. Input/
A: Power Supply Pin No. Signal name
output
B: Input 11 EGR valve C
C: Ground/Shield/Return 12 NC(*) —
D: Output 13 Engine oil pressure sensor D
E: Communication 14 NC(*) —
CN-CE01 15 Coolant temperature sensor D
Input/ 16 5V electric power supply for sensor A
Pin No. Signal name
output 17 NC(*) —
1 NC(*) — 18 NC(*) —
2 NC(*) — 19 EGR valve position sensor D
3 Atmosphere sensor D 20 NC(*) —
4 Supply pump #1 (+) B 21 NC(*) —
5 Supply pump #1 (–) C 22 EGR valve (+) B
6 CAN(+) C 23 Boost temperature sensor D
7 NC(*) — 24 NC(*) —
8 CAN(+) B 25 Common rail pressure sensor D
9 Supply pump #2 (+) B 26 Buckup sensor D
10 Supply pump #2 (–) C 27 NE sensor (+) D
*: Never connect to NC or malfunctions or failures will *: Never connect to NC or malfunctions or failures will
occur. occur.
4 PC400, 450-7E0
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
28 NC(*) — 13 NC(*) B
29 NC(*) — 14 NC(*) B
30 Fuel temperature sensor D 15 NC(*) B
31 NC(*) — 16 NC(*) B
32 NC(*) — 17 NC(*) B
33 5 V electric power supply for sensor A 18 NC(*) B
34 NC(*) — 19 NC(*) B
35 NC(*) — 20 NC(*) E
36 NC(*) — 21 NC(*) A
37 5 V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC(*) — 24 NC(*) B
40 NC(*) — 25 NC(*) B
41 NC(*) — 26 NC(*) B
42 NC(*) — 27 NC(*) B
43 NC(*) — 28 NC(*) B
44 Boost pressure sensor D 29 NC(*) C
45 Injector #1 (+) B 30 NC(*) B
46 Injector #5 (+) B 31 NC(*) B
47 Sensor GND C 32 NC(*) C
48 Ne sensor (–) C 33 GND C
49 NC(*) — 34 NC(*) C
50 NC(*) — 35 NC(*) B
51 Injector #2 (–) C 36 NC(*) B
52 Injector #3 (–) C 37 NC(*) C
53 Injector #1 (–) C 38 NC(*) D
54 Injector #2 (+) B 39 Key switch (ACC) B
55 Injector #3 (+) B 40 Electrical intake air heater relay drive D
56 Injector #4 (+) B 41 NC(*) D
57 Injector #6 (+) B 42 Electrical intake air heater relay return C
58 Injector #4 (–) C 43 NC(*) D
59 Injector #6 (–) C 44 NC(*) D
60 Injector #5 (–) C 45 NC(*) —
*: Never connect to NC or malfunctions or failures will 46 CAN(+) E
occur. 47 CAN(–) E
48 NC(*) D
CN-CE02 PWM OUTPUT
49 D
Input/ (Power train relay output)
Pin No. Signal name
output 50 NC(*) D
1 NC(*) B *: Never connect to NC or malfunctions or failures will
2 NC(*) B occur.
3 NC(*) B
4 NC(*) B CN-CE03
5 NC(*) B Input/
Pin No. Signal name
6 NC(*) B output
7 NC(*) B 1 GND C
8 NC(*) B 2 NC(*) C
9 Fuel control dial (+) B Electric power supply
3 A
10 NC(*) E (+24V constantly)
11 NC(*) B 4 NC(*) A
12 NC(*) B *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
PC400, 450-7E0 5
Rotation sensor
1. Connector
2. Sensor
3. O-ring
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
6 PC400, 450-7E0
Ambient pressure sensor
1. Connector
2. Pressure import port
Boost pressure sensor
1. O-ring
2. Sensor
3. Connector
PC400, 450-7E0 7
Boost temperature sensor
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor, hydraulic oil temperature sensor
1. Connector
2. Sensor
3. O-ring
8 PC400, 450-7E0
EGR valve stroke sensor
1. Core
2. O-ring
3. Sensor
4. Connector
PC400, 450-7E0 9
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
10 PC400, 450-7E0
Electronic control system 1
Control function
1
Engine and pump composite control function
Pump and valve control function
Power maximizing function
Machine push-up function
Auto-deceleration function
Auto-warm-up and overheat prevention function
Electronic control system

6
Swing control function
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
Machine control system diagram
12 PC400, 450-7E0
PC400, 450-7E0 13
1. Engine and pump composite control function
14 PC400, 450-7E0
Function 1) Control method in each mode

q This function allows the operator to select P and E modes
proper engine torque and pump absorption q Matching point in P mode: Rated speed
torque according to the type of work. Four
modes are provided: P, E, B and L. Using the Mode Matching point
work mode switch on the monitor panel, the 246.3 kW/1,850 rpm
operator is required to select one of them. P
{330 HP/1,850 rpm}
q The pump controller detects the speed of the
213.3 kW/1,720 rpm
engine governor set with the fuel control dial E
{286 HP/1,720 rpm}
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, q If the pump load increases and the pres-
according to the pump absorption torque set in sure rises, engine speed (N) lowers. At
each mode. 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 con-
troller constantly uses the engine near the
maximum output point.
PC400, 450-7E0 15
B and L modes
Mode B mode L mode

Partial output point 82% 61%
Mode Matching point

194.9 kW/1,730 rpm
B
{261 HP/1,730 rpm}
150.8 kW/1,250 rpm
L
{202 HP/1,250 rpm}
q 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 main-
taining engine torque (T) constant along
the constant horsepower curve. This
ensures reduced fuel consumption.
16 PC400, 450-7E0
2) Function to control pump during travel 3) Function to control when emergency pump
q Traveling the machine in E or B mode drive switch is turned on
leaves the working mode unchanged, but q Even if any abnormality occurs in the controller
raises the pump absorption torque and or sensor, setting emergency pump drive
engine speed (N) to values same as those switch (10) to the “ON” position activates the
in P mode. machine with an absorption torque approxi-
q If the machine travels in L mode, the work- mately equivalent to that in E mode.
ing mode and engine speed (N) do not In this case, a constant current flows from the
change, but the pump absorption torque is battery to the EPC valve for PC and therefore,
increased. the oil pressure is sensed by only the EPC
valve for PC.
PC400, 450-7E0 17
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) LS control function 3) 2-stage relief function

q Depending on the operation condition of q The relief pressure in the normal work is
the actuator, this function changes the 34.8 MPa {355 kg/cm 2 }. If the 2-stage
pressure output from the LS-EPC valve to relief function is turned on, however, the
LS valve to change the change point (LS relief pressure rises to about 37.2 MPa
set differential pressure (DLS)) of the {380 kg/cm 2 }. By this operation, the
pump discharge in the LS valve. hydraulic force is increased further.
q By this operation, the start-up time of the
pump discharge is optimized and the com- Operating condition for turning on
Relief pressure
posite operation and fine control perfor- 2-stage relief function
mance is improved. • During travel
• When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
• When boom is lowered O
• When power maximizing function is 37.2 MPa
turned on {380 kg/cm2}
• When L mode is operated
2) Cut-off function
q 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
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 oper-
ator to increase the boom pushing force by
operating the machine push-up switch.
20 PC400, 450-7E0
1) Power maximizing function 2) Machine push-up function

q This function is used to increase digging q The machine push-up function allows the
force for a certain period of time (e.g., operator to increase the boom pushing
when digging up a large rock). force that is required for ditching or mass
q If the left knob switch is pressed in P or E excavation in hard ground by operating
mode, the hydraulic force is increased machine push-up switch (1).
about 7% to increase the digging force.
Each function is set automatically as 2-stage safety valve
Switch
shown below. function
Setting of safety valve at
Function Setting boom cylinder head
OFF
Engine and pump Matching at rated output 14.7 MPa
control point {150 kg/cm2}
34.8 MPa Setting of safety valve at
{355 kg/cm2} boom cylinder head
ON
2-stage relief function O 28.4 MPa
37.2 MPa {290 kg/cm2}
{380 kg/cm2}
Software cut-off function Cancel
q These settings are automatically reset after

8.5 seconds when the switch is pressed.
PC400, 450-7E0 21
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 (approxi-
mately 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 opera-
tion level, the engine speed instantly rises to
the level set with the fuel control dial.
22 PC400, 450-7E0
5. 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 tem-
perature is too high during operation to protect
the engine from overheating.
PC400, 450-7E0 23
1) Auto-warm-up function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised auto-
matically to warm up the engine.
Operating condition (All) Operated

Coolant temperature: Below 30°C.
Engine speed: Max. 1,200 rpm ⇒ Engine speed: Max. 1,200 rpm
⇓
Resetting condition (Any one) Reset
⇒
Coolant temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3
Manual
sec. or longer
2) 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 95°C.
Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature:
Hydraulic oil
temperature:
Above 95°C
⇒ Work mode: Travel
Engine speed: Keep as is.
Lower travel speed.
⇒ Below 95°C
• Under above condition, controller
is set to condition before opera-
tion of function. (Automatic reset)

Hydraulic oil or coolant temperature:
⇒ ⇒
Hydraulic oil or Work mode: P or E mode Below 100°C
coolant temperature: Engine speed: Keep as is. • Under above condition, controller
Above 100°C Lower pump discharge. is set to condition before opera-
tion of function. (Automatic reset)

Work mode: P, E, B or L mode Hydraulic oil or coolant temperature:
⇒ ⇒
Hydraulic oil or Engine speed: Keep as is. Below 102°C
coolant temperature: Monitor alarm lamp: Lights • Under above condition, controller
Above 102°C up. is set to condition before opera-
Lower pump discharge. tion of function. (Automatic reset)

Hydraulic oil or coolant temperature:
Below 105°C
Work mode: Any mode
⇒ ⇒
Hydraulic oil or Fuel control dial: Return to low idle
Engine speed: Low idle
coolant temperature: position once.
Monitor alarm lamp: Lights up
Above 105°C • Under above condition, controller
Alarm buzzer: Sounds
is set to condition before opera-
tion of function. (Manual reset)
24 PC400, 450-7E0
6. Swing control function
Function
The swing lock and swing holding brake function
are provided as a swing control function.
PC400, 450-7E0 25
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function when
tion swing lock switch is turned on
q The swing lock function (manual) is used q If swing lock switch (4) is turned on, the
to lock machine from swinging at any posi- pump cut-off function is cancelled and the
tion. The swing holding brake function relief pressure rises from 34.8 MPa {355
(automatic) is used to prevent hydraulic kg/cm2} to 37.2 MPa {380 kg/cm2}. If the
drift after the machine stops swinging. work equipment is relieved under this con-
q Operation of swing lock switch and swing dition, the hydraulic oil temperature rises
lock/holding brake quickly and the warm-up time can be
shortened.
Lock Lock Func-
Operation
switch lamp tion
If swing lever is set in
neutral, swing brake
Swing operates in about 7 sec.
OFF OFF holding If swing lever is oper-
brake ated, brake is released
and machine can swing
freely.
Swing lock operates and
machine is locked from
swinging.
Swing
ON ON Even if swing lever is
lock
operated, swing lock is
not reset and machine
does not swing.
Swing holding brake release switch

q If the controller, etc. has a problem, the
swing holding brake does not work nor-
mally, 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 hydrau-
lic brake is applied by the safety valve.
Note that if swinging is stopped on a
slope, the upper structure may swing by
its gravity.
Swing
holding ON OFF
brake (when controller has (when controller is nor-
release trouble) maly)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing lock
Swing holding
is turned is can- is turned
brake brake is
on. celed. on.
turned on.
26 PC400, 450-7E0
7. 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
1) Pump control function during travel 2) Travel speed change function

q If the machine travels in a work mode 1] Manual change with travel speed switch
other than P mode, the work mode and If one of Lo, Mi and Hi is selected with the
the engine speed are kept as they are and travel speed switch, the pump controller
the pump absorption torque is increased. controls the pump capacity and motor
q For details, see "Engine and pump com- capacity at each gear speed as shown
posite control function." below to change the travel speed.
Mi (Mid-
Travel speed Lo (Low Hi (High
ium
switch speed) speed)
speed)
Pump capacity (%) 90 80 100
Motor capacity Max. Max. Min.
Travel speed
3.3 4.4 5.5
(km/h)
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 trav-
elling on level ground or travelling down-
hill, and the travel pressure goes below
18.6 MPa {190 kg/cm2} for more than 0.5
sec, the travel motor capacity will auto-
matically change and will return to Hi or
Mi.
28 PC400, 450-7E0
8. Attachment flow control and circuit selector function (if equipped)
Function
q This function is available only with the attach-
ment 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
9. System component parts

1) PPC oil pressure switch
1. Plug
2. Switch
3. 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 trans-
mit it to the pump controller.
30 PC400, 450-7E0
2) Oil pressure sensor
1. Sensor
2. Connector
Function q The relationship between the pressure applied

q The pump pressure sensor is installed to the to sensors (P) and output voltage (E) is shown
input circuit of the control valve. in the figure below.
q It converts the pump discharge pressure into a
voltage and transmits it to the pump controller.
Operation
q 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 ampli-
fier).
q The amplifier magnifies output voltage (E) and

transmits it to the pump controller.
PC400, 450-7E0 31
3) Pump pressure sensor (high pressure)
1. Sensor
2. 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) Pump controller
PC400, 450-7E0 33
CN-CP01 CN-CP02
Input/ Input/
output output
1 NC(*) Input 1 NC(*) output
2 R pump pressure sensor Input 2 Emergency swing parking switch Input
3 NC(*) Input 3 NC(*) Input
4 NC(*) – 4 232C_RXD Input
7 NC(*) Input 7 Machine select 4 (ATT) Input
8 F pump pressure sensor Input 8 Service circuit SOL signal output
10 GND (SIG) – 10 NC(*) Input
11 Knob switch Input 11 NC(*) output
12 NC(*) Input 12 CAN_SH –
13 Bucket digging pressure sensor Input 13 Machine select 5 (ATT) Input
14 NC(*) Input 14 232C_TXD output
16 NC(*) output 16 Travel steering signal Input
17 Key switch (C-terminal) Input 17 Machine select 3 Input
19 Arm digging pressure sensor Input 19 NC(*) output
21 NC(*) – Input/
21 NC(*)
22 POT-PWR output output
23 Key switch (ACC-terminal) Input Input/
22 CANO_L
24 NC(*) Input output
*: Never connect to NC or malfunctions or failures will Input/
23 NC(*)
occur. 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
*: Never connect to NC or malfunctions or failures will
occur.
34 PC400, 450-7E0
CN-CP03
Input/
Pin No. Signal name
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
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
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
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.
PC400, 450-7E0 35
Monitor system 1
q 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 immedi-
ately 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 temper-
ature, hydraulic oil temperature and fuel
level
q The machine monitor also has various mode
selector switches and functions to operate the
machine control system.
36 PC400, 450-7E0
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC400, 450-7E0 37
Input and output signals
CN-1 CN-3
Input/ Input/
output output
1 Key ON Input 1 NC (*) Input
2 Key ON Input 2 NC (*) Input
3 Window washer motor output output 3 NC (*) Input
4 Starting signal Input 4 NC (*) Input
5 Limit switch (W) Input 5 NC (*) Input
6 GND – 6 NC (*) Input
7 GND – 7 RS230C CTS Input
8 VB+ Input 8 RS230C RXD Input
9 Wiper motor (+) output Input/
9 RS230C RXD
10 Wiper motor (–) output output
11 Buzzer ON signal Input Input/
10 RS230C RXD
12 Limit switch (P) Input output
11 BOOTSW Input
12 NC (*) Input
CN-2
13 GND –
Input/
Pin No. Signal name 14 CAN (SHIELD) Input
output
15 CAN (+) Input
1 Engine coolant temperature Input
16 CAN (–) Input
2 Fuel level Input
3 Radiator coolant level Input
occur.
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.
38 PC400, 450-7E0
Monitor control and display portion

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

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power max. switch status Power max. monitor status

Lights up but goes out after approx.
Power max. Being pressed
9 sec. when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
40 PC400, 450-7E0
Temperature or
Gauge Range Indicator Buzzer sound
volume
A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Green
temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red Q
B2 102 Red
Hydraulic oil B3 100 Green
temperature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 467 Green
C2 381 Green
Fuel level C3 295 Green
(l) C4 147.5 Green
C5 114 Green
C6 80.5 Red
PC400, 450-7E0 41
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.
Check before When engine is When engine is

Symbol Display item
starting item stopped running
When abnormal,
Engine oil pressure ● — lights up and buzzer
sounds
Lights up when
Battery charge ● —
abnormal
When abnormal,
Radiator coolant Lights up when
● lights up and buzzer
level abnormal
sounds
Lights up when
Engine oil level ● —
abnormal
Lights up when
Air cleaner clogging ● —
abnormal
Lights up when there is a warning. Lights up

Maintenance 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 Black on
(Max. B6 or equivalent) white background
Normal (B6 – B2) No display
High temperature White on
(Min. B2) red background
42 PC400, 450-7E0
Display category Symbol Display item Display range Display method
INT ON OFF Displays set con-

Wiper
dition
Displays set
Working mode
mode
Monitor
Displays set
Travel speed
speed
Auto-decelera- Displays actua-

ON ⇔ OFF
tion tion status
Lights up when
Service meter
Service meter When service meter is working service meter is
indicator
working
PC400, 450-7E0 43
Switches
1. Working mode selector switch

2. Selector switch
3. Buzzer cancel switch
4. Display brightness, contrast adjustment switch
5. Control switch
6. Window washer switch
7. Wiper switch
8. Maintenance switch
9. Travel speed selector switch
10. Auto-deceleration switch
44 PC400, 450-7E0
Working mode selector switch Wiper switch

Press one of the P, E, B and L switches to set the Each time the wiper switch is pressed, the wiper
desired working mode. It is possible to check which setting changes as shown below.
mode is active with the working mode monitor. The OFF o INT o ON o OFF o…..
relationship between each working mode and the The wiper settings can be viewed on the wiper
monitor display is shown in the table below. monitor. The relationship between the wiper setting
and the monitor display is shown in the table below.
Switch that Dis- Working mode status
is pressed play after setting Display Setting Wiper actuation status
[P] P P mode (default) Stowing stopped or
None OFF
[E] E E mode now stowing
[L] L L mode Wiper symbol
INT Intermittent actuation
+ INT
[B] B B mode
Wiper symbol
ON Continuous actuation
+ ON
Selector switch
This is used when making detailed settings in each
Window washer switch
working mode. For details, see "Attachment flow
control function". While the switch is being pressed, window washer
liquid is sprayed out. There is a time delay before
Buzzer cancel switch the wiper starts.
Pressing this switch when the alarm buzzer is mak-
ing sound stops the alarm buzzer. Control switch
If a new abnormality is detected, the alarm buzzer This is used for control when using the mainte-
sounds. nance function or select function. For details, see
Depending on the alarm buzzer type, it does not each function.
stop even if you press the buzzer cancel switch.
Display brightness, contrast adjustment switch
Maintenance switch This function is used to adjust the brightness and
Check the condition of the maintenance items. For contrast of the display. For details, see each func-
details, see "Maintenance function". tion.
Auto-deceleration switch
The auto-deceleration switch toggles the auto-
deceleration 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 set-
ting 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
Select mode function

1. Setting of oil flow
q This is used when setting the flow in each
working mode.
q It is available when genuine attachment piping
is i nstal led and Atta chm ent i ns ta lle d i s
selected with the initial value setting function
on the service menu.
q 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
3) Press control switch (2) and select the
B mode [B] + flow symbol flow level.
Control switch Actuation
Flow level bar graph
extends to the right
retracts to the left
Method of use
a Carry out the setting on the normal screen
P mode, E mode
1) Press select switch (1).
4) After completing the level selection, press
input confirmation switch (3). The selec-
tion 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 relation-
ship between the flow level and the flow is
shown in the table below.
Flow level Flow (l/min) Remarks
8 550 Default
7 476
6 401
5 327
4 253
2) When the screen changed as below,
select "01" by operating switch (2), and 3 179
press input confirmation switch (3). 2 104
1 30
a 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.
46 PC400, 450-7E0
B mode 9) After the flow level is confirmed, the

5) Press select switch (1). screen changes to the screen shown in
6) When the screen changed as below, the diagram below. With this screen, it is
select "01" by operation switch (2), and possible to make fine adjustment to the
press input confirmation switch (3). flow.
7) Select one of the three flow levels by mov- Control switch Actuation
ing the cursor with operation switch (2) or Flow level bar graph
entering the relevant number (01, 02 or extends to the right
03) with the 10-key pad. Flow level bar graph
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.
When flow When flow When flow
Flow
is 100 l/ is 140 l/ is 180 l/ Remarks
level
min. min. min.
7 200 280 360
6 180 260 340
q The relationship between the flow
level and the flow is shown in the 5 160 240 320
table below. 4 140 220 300 Default
No. Flow (l/min) Remarks 3 120 200 280
01 230 Default 2 100 180 260
02 190 1 80 160 240
03 150
a Flow level is not finalized until input
confirmation switch (3) is pressed.
8) Pressing input confirmation switch (3) Returning to the normal screen by
after selecting the flow level finalizes the pressing return switch (4) will leave
selection. the flow level setting unchanged.
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 47
11) Check the set value with the working 3) The setting value adjusting screen shown
mode monitor. The relationship between below is displayed. Operate operation
the display level and the set value is switch (2) to select the setting value.
shown in the table below. Relationship between fuel mileage and
work rate for each of the setting values is
Display level Set value (l/min.)
as follows.
8 220 or 360 E0: Initial Setting Value
7 200 or 340 (highest priority is placed on work
6 180 or 320 rate.)
E1: Economy Adjusting 1
5 160 or 300
(Priority is placed on work rate.)
4 140 or 280 E2: Economy Adjusting 2
3 120 or 260 (Priority is placed on fuel mileage.)
2 100 or 240 E3: Economy Adjusting 3
(highest priority is placed on fuel mile-
1 80
age.)
2) 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.
1) Press select switch (1).
a As the item goes lower, the fuel mile-

age is improved while, on the other
hand, the work rate is decreased.
4) Press input confirmation switch (3) to con-
firm the setting value.
2) The screen shown below is displayed.

Operate operation switch (2) to select "02"
and then press input confirmation switch
(3).
5) Press return switch (4) to return to the

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

q This function alerts the operator when routine a Carry out the setting on the normal screen
maintenance (replacement, inspection or filling 1) Press maintenance switch (1) and switch
for the 11 maintenance items) is due. to the maintenance list display screen.
q When maintenance switch (1) is pressed, any The maintenance items are displayed as
maintenance item that is due is displayed yel- symbols on the screen.
low or red for 30 seconds. 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 dis-
played in red.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500 2. Maintenance operation
02 Engine oil filter 500 1) After completing the selection, press input
03 Fuel main filter 1000 confirmation switch (3). The screen will
41 Fuel prefilter 500 change to the maintenance reset screen.
04 Hydraulic filter 1000 2) The maintenance reset screen shows the
time remaining before maintenance is
05 Hydraulic tank breather 500
due. To reset the remaining time, press
06 Corrosion resistor 1000(*) input confirmation switch (3). When input
07 Damper case oil 1000 confirmation switch (3) is pressed, the
08 Final case oil 2000 screen changes to the check screen. To
09 Machinery case oil 1000 return to the maintenance list screen,
10 Hydraulic oil 5000 press return switch (4).
*: If equipped (To be determined)
q The content of the caution display differs

according to the remaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (white
with less than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
PC400, 450-7E0 49
3) The check screen shows the symbol for

the selected maintenance item and the set
time in large letters.
4) 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 return
to the maintenance list screen without
resetting the remaining time, press return
switch (4).
5) On the maintenance 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.
50 PC400, 450-7E0
Brightness, contrast adjustment function 1

This function is used to adjust the brightness and 2) Press operation switch (2), or use the 10-
contrast of the display. key pad to input the number (01 – 02) to
a Carry out the setting on the normal screen select either contrast or brightness.
3) After completing the selection, press input
1. Adjustment method confirmation switch (3) to return to the
1) Press display brightness/contrast adjust- adjustment screen. Pressing return switch
ment switch (1) and switch to the adjust- (4) without pressing input confirmation
ment screen. switch (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.
4) Press operation switch (2) and adjust the

brightness or contrast as desired.
Control switch Actuation
extends to the right

q Relationship between menu symbol

and content.
No. Symbol Content
00 Return mark Return
01 Contrast
02 Brightness
PC400, 450-7E0 51
Service meter check function 1 Display LCD check function

q With the starting switch in the OFF position, q On the normal screen, if monitor return switch
pressing return switch (1) while holding down (1) and working mode switch "P" (2) are kept
operation switch (2) of the monitor for 3 to 5 pressed at the same time, the whole screen
seconds displays the service meter. will become white. If any part of the display is
q When the 2 switches are released, the display black, the LCD is broken.
goes out.
52 PC400, 450-7E0
User code display function q If there are more than one service or failure
q If there is any problem in operating the codes, they are displayed in turn every 2 sec-
machine, the user code is displayed on the onds.
monitor to advise the operator of the steps to q Any service codes/failure codes that are not
take. This code appears on the normal screen. related to the displayed user code is displayed
q On the normal screen, the user code is dis- with this function.
played on the portion for the hydraulic oil tem-
perature gauge in the center of the screen.
q If the telephone number has been set using the

service menu, the screen shows the service
q If there are more than one user codes, they are code/failure code as well as telephone symbol
displayed in turn every 2 seconds. and telephone number. For details of inputting
the telephone number, see "Special functions
of monitor panel" in the "Testing and adjusting"
section.
q While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
Both service code and failure code identify the
cause of problem corresponding to the dis-
played user code.
PC400, 450-7E0 53
Sensor 1
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is
always connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Hydraulic oil Resis-
— —
temperature tance
Resis-
Coolant temperature — —
tance
Resis-
Fuel level — —
tance
ON OFF
Air cleaner clogging Contact
(Closed) (Open)
Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
54 PC400, 450-7E0
Hydraulic oil temperature sensor, coolant temperature sensor 1
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Fuel level sensor 1
1. Float 3. Cover
2. Connector 4. Variable resistor
PC400, 450-7E0 55
Air cleaner clogging sensor 1
56 PC400, 450-7E0
KOMTRAX system 1
q The KOMTRAX system transmits various kinds

of machine information wirelessly. Persons to
operate the KOMTRAX can refer to the infor-
mation at office to provide various kinds of ser-
vices for customers.
q Information transmittable from the KOMTRAX
system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
PC400, 450-7E0 57
KOMTRAX terminal 1
TC301
1. Communication antenna connector q The KOMTRAX terminal sends various

2. GPS antenna connector machine information based on the network sig-
3. Machine harness connector (DEUTSCH-40P) nals and input signals obtained through the
machine monitor, as well as GPS position
d ata, v i a wi r e l e s s c om m u ni c a t i on . T h e
KOMTRAX terminal can send information via
communication antenna.
q Conditions of the KOMTRAX terminal can be
checked with the “Display of KOMTRAX sys-
tem s etti ng” in the s erv ic e mode of the
machine monitor.
q Use of KOMTRAX terminal must be limited for
the countries in which such communication is
allowed.
q When using TC301 in countries other than
Japan, you must notify the name of the country.
Input and output signals
DEUTSCH-40P [CN-G01]
Input/Output Input/Output
signal signal
1 NC — 21 Input for check 0 Input
2 NC — 22 Input for check 1 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 CAN shield GND — 26 NC —
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch (ACC) Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Constant power source (12/24V) Input
20 Relay output Output 40 Constant power source (12/24V) Input
58 PC400, 450-7E0
PC400, 450-7E0 59
SEN03593-02

© 2009 KOMATSU
All Rights Reserved
60
SEN03595-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
20 Standard value table 1

Standard service value table
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 1
SEN03595-02 20 Standard value table
Standard value table for engine related parts 1

PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Engine SAA6D125E-5
Item Measurement conditions Unit Standard value Permissible value

High idle rpm 1,930 ± 50 1,930 ± 50
Engine speed Low idle rpm 1,000 ± 25 1,000 ± 25
Rated speed rpm 1,900 1,900
kPa Min. 133
Intake air pressure At rated output 107 {800}
{mmHg} {Min. 1,000}
Exhaust gas
All speed range (intake air temp: 20°C) °C Max. 700 700
temperature
%
At sudden acceleration (Low o High) {Bosch Max. 25 {Max. 2.5} —
index}
Exhaust gas color Bosch
At rated output Max. 1.5 —
index
Bosch
At high idle Max. 1.0 —
index
Normal Intake valve mm 0.33 —

Valve clearance
temperature Exhaust valve mm 0.71 —
MPa
At low idle Min. 1.18 {Min. 12} —
EGR valve drive {kg/cm2}
pressure MPa Min. 1.43
At high idle —
{kg/cm2} {Min. 14.6}
Engine oil temperature: 40 – 60°C MPa

Compression pressure Min. 2.9 {Min. 30} 2.0 {200}
Engine speed: 200 – 250 rpm {kg/cm2}
At rated output kPa Max. 1.47
Blow-by pressure 2.94 {300}
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 150}
At rated output
Engine oil SAE0W30E0S, MPa 0.29 – 0.69
0.18 {1.8}
temperature: SAE5W40E0S, {kg/cm2} {3.0 – 7.0}
Min. 80°C SAE10W30DH,
Oil pressure
At low idle SAE15W40DH,
Engine oil SAE30DH MPa Min. 0.08
engine oil 0.05 {0.5}
temperature: {kg/cm2} {Min. 0.8}
Min. 80°C
Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Fan belt, alternator belt Deflection when pressed with finger force
mm 13 – 16 13 – 16
tension of approx. 58.8 N {6 kg}
2 PC400, 450-7E0
20 Standard value table SEN03595-02
Standard value table for chassis related parts

(Backhoe specification) 1
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature:
2 pumps at relief 1,930 ± 100 1,930 ± 100
• Engine at high idle
• Arm in relief condition
Engine speed

At 2-pump relief + one rpm
Within operating range 1,830 ± 100 1,830 ± 100
touch power up
• Arm relief + power max. switch
in ON condition
Speed when auto- • Auto-deceleration switch in ON
deceleration is oper- condition 1,300 ± 100 1,300 ± 100
ated • All control levers in NEUTRAL
condition
Boom control valve l l a b l a b
Arm control valve a b
Spool stroke
Bucket control valve

mm 9.5 9.5 9.5 9.5
Swing control valve – –
± 0.5 ± 0.5 ± 0.5 ± 0.5
Travel control valve

BLP00101
Boom control lever 85 ± 10 85 ± 10

Travel of control levers
Arm control lever • Engine stopped 85 ± 10 85 ± 10

Bucket control lever • At center of control lever grip 85 ± 10 85 ± 10
• Max. reading up to stroke end mm
Swing control lever (excepting lever play in NEU- 85 ± 10 85 ± 10
Travel control lever TRAL position) 115 ± 12 115 ± 12
Play of control levers Max. 10 Max. 15
15.7 ± 4.9 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.5}
Operating effort of control levers
15.7 ± 4.9 Max. 24.5

Arm control lever
• Hydraulic oil temperature: {1.6 ± 0.4} {Max. 2.5}
Within operation range 12.7 ± 2.9 Max. 21.6
Bucket control lever • Engine at high idle {1.3 ± 0.3} {Max. 2.2}
• Hydraulic oil temperature: N {kg}
Within operating range 12.7 ± 2.9 Max. 21.6
Swing control lever
• At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end 24.5 ± 5.9 Max. 39.2
Lever
Travel {2.5 ± 0.6} {Max. 4.0}
control 74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
PC400, 450-7E0 3
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory
Within operation range
4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Working mode: P mode
{42 ± 10} {42 ± 10}
• Hydraulic pump output pressure
with all control levers in NEU-
TRAL position
34.81 +1.47
–0.98 33.34 – 36.77
RAISE (37.27 +1.47
–0.98 ) (35.79 – 39.23)
{340 – 375 (365 – 400)}
{355+15 +15
–10 (380 –10 )}
• Hydraulic oil
Boom temperature: At low-pres- 18.14 ± 0.98 16.67 – 19.61
sure setting {185 ± 10} {170 – 200}
LOWER
Within opera-
tion range At high-
31.38 ± 1.47 29.2 – 33.34
• Engine at high pressure
{320 ± 15} {300 – 340}
idle setting
• Working mode: P mode 34.81 +1.47 33.34 – 36.77
–0.98
• Hydraulic pump output pressure (35.79 – 39.23)
Arm
with all measurement circuits (37.27 +1.47
–0.98 ) {340 – 375
relieved {355 –10 (380 +15
+15
–10 )} (365 – 400)}
• Values inside parenthesis:
34.81 +1.47 33.34 – 36.77
Hydraulic oil pressure with –0.98
(35.79 – 39.23)
(37.27 +1.47
Hydraulic pressure
Bucket power max. switch in ON mode –0.98 ) {340 – 375

(reference only) {355 –10 (380 +15
+15
–10 )} (365 – 400)}
MPa
{kg/cm2} 30.89 +1.47
–2.45 27.95 – 32.85
Swing
{315 +15 {285 – 335}
–25 }
37.27 +2.94
–0.98 35.79 – 40.70
Travel
{380 +30 {365 – 415}
–10 }
Control circuit source • Engine at high idle 3.24 ± 0.2 2.84 – 3.43
pressure • Self pressure reducing valve {33 ± 2} {29 – 35}
output pressure with all control
levers in NEUTRAL position
• Hydraulic oil tem- When all
perature: Within control
4.2 ± 1.0 4.2 ± 1.0
operation range levers in
{42 ± 10} {42 ± 10}
• Engine at high idle NEUTRAL
• Working mode: P position
LS differential pressure
mode When trav-
• Traveling speed: Hi eling at half
• Hydraulic oil pump 2.65 ± 0.1 2.65 ± 0.1
stroke
pressure – LS {27 ± 1} {27 ± 1}
(without
pressure load)
PPC valve output Within operation range 2.9 +0.6
–0.2 2.9 +0.6
–0.2
pressure • Engine at high idle {30 +5.5 {30 +5.5
–1.5 } –1.5 }
• Control lever full stroke
4 PC400, 450-7E0
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory
• Hydraulic oil temperature: deg. PC400: Max. 120 PC400: Max. 150
Swing brake angle
Within operating range (mm) PC450: Max. 130 PC450: Max. 160
• Bucket: Empty
• Working mode: P mode
• Swing circle misalignment amount
when stopping after one turn
90° 3.7 ± 0.4 Max. 4.6

Time taken to start Within operation range sec.
swing • Bucket: Empty
180° 5.4 ± 0.5 Max. 6.4
• Time required for passing
points 90 and 180° from
starting point
Swing
Time taken to swing • Hydraulic oil temperature: sec. 33.0 ± 3.3 Max. 38
• Bucket: Empty
• Time required for 5 more turns
after making initial one turn
• Hydraulic oil temperature: Within

Hydraulic drift of swing operation range mm 0 0
• Engine stopped
• Keeping upper structure trans-
verse on slope of 15°
• Notching a mating mark on inner
and outer races of swing circle
• Mating mark misalignment amount
during 5 minutes
PC400, 450-7E0 5
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory
operation range
Swing
Leakage from swing • Engine at high idle

l/min Max. 5.5 Max. 11
motor • Swing lock switch: ON
• Leakage amount for one minute
during swing relief
STD: 63.2 ± 12.6 STD: 42.0 – 80.0

Lo
LC: 67.3 ± 13.5 LC: 45.0 – 84.5
Travel speed
sec. STD: 45.1 ± 6.8 STD: 31.5 – 55.0
(Idle travel) • Hydraulic oil temperature: Mi
LC: 48.1 ± 7.2 LC: 34.0 – 58.0
• Time required for track shoes STD: 34.5 ± 35 STD: 28.0 – 41.5
Hi
to make 5 turns after making LC: 36.7 ± 3.6 LC: 32.0 – 44.0
one initial idle turn
Lo 24.0 ± 4.8 18.9 – 31.0
Travel speed
• Hydraulic oil temperature: Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel)
Travel
• Flat ground
• Time required for traveling 20 Hi 13.1 – 1.3 11.7 – 15.1
m after 10 m trial run

operation range
• Engine at idle
Travel deviation mm Max. 200 Max. 300
• Travel speed: Lo
• Solid and flat ground
• Swerving amount while traveling
20 m (X) after initial 10 m trial run.
6 PC400, 450-7E0
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory
Hydraulic drift of travel mm 0 0

Travel
• Engine stopped
• Parking machine on slope 12° with
sprocket facing upslope
• Sliding distance for 5 minutes
Leakage of travel motor l/min Max. 20 Max. 40
• Travel: Lock sprocket.
• Oil leakage amount for one minute
with traveling in relief condition
Whole work
PC400: Max. 600 PC400: Max. 900
equipment (tooth
PC450: Max. 700 PC450: Max. 1,050
tip fall amount)
Hydraulic drift of work equipment
Boom cylinder
PC400: Max. 25 PC400: Max. 38
(cylinder retrac-
Work equipment
• Hydraulic oil temperature: Within PC450: Max. 29 PC450: Max. 44

tion amount)
operation range
• Flat and level ground mm
Arm cylinder (cyl- • Work equipment in measurement
PC400: Max. 85 PC400: Max. 128
inder extension posture as illustrated above
PC450: Max. 100 PC450: Max. 150
amount) • Bucket load: 3,060 kg
• Engine stopped
• Work equipment control lever in
Bucket cylinder NEUTRAL position
PC400: Max. 30 PC400: Max. 45
(cylinder retrac- • Fall amount for 15 minutes as
PC450: Max. 35 PC450: Max. 53
tion amount) measured every 5 minutes start-
ing immediately after initial setting
PC400, 450-7E0 7
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
RAISE
PC400: 4.0 ± 0.4 PC400: Max. 4.8
PC450: 4.2 ± 0.4 PC450: Max. 5.0
Boom • Hydraulic oil temperature:

LOWER
• Working mode: P mode PC400: 2.9 ± 0.3 PC400: Max. 3.4
• Time required from raise PC450: 2.8 ± 0.3 PC450: Max. 3.3
stroke end till bucket
touches ground
CURL
PC400: 4.3 ± 0.4 PC400: Max. 5.0
Work equipment speed
PC450: 4.7 ± 0.5 PC450: Max. 5.4

Work equipment
Arm • Hydraulic oil temperature: sec.

DUMP
• Time required from dump- 3.6 ± 0.4 Max. 4.3

ing stroke end to digging
stroke end
CURL
3.6 ± 0.4 Max. 4.3
Bucket • Hydraulic oil temperature:

DUMP
• Working mode: P mode 2.9 ± 0.3 Max. 3.5

• Time required from dump-
ing stroke end to digging
stroke end
8 PC400, 450-7E0
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Boom sec. Max. 3.0 Max. 3.6

• Engine at low idle
• Time required from raise stroke
end till bucket touches ground
and pushes up machine front
• Hydraulic oil temperature: PC400: Max. 3.0 PC400: Max. 3.6

Time lag
Arm
Within operation range PC450: Max. 4.0 PC450: Max. 4.6
Work equipment

• Time required from dumping
stroke end till bucket stops
momentarily after control lever
is tilted to digging and starts to
move again
sec.

Bucket Within operation range Max. 3.0 Max. 5.0
• Time required from dumping
stroke end till bucket stops
momentarily after control lever
is tilted to digging and starts to
move again

Internal leakage
Cylinders 4.5 20
cc/min
• Leakage amount for one
Center swivel minute with cylinder or travel to
10 50
joint be measured in relief condition
PC400, 450-7E0 9
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate-
gory

Performance in compound operation

• Traveling speed: Lo
• Flat and level ground
Swerving amount in • Swerving amount (X) when
simultaneous opera- traveling 20 m after initial trial
mm Max. 400 Max. 440
tion of work equip- run of 10 m
ment and travel
hydraulic pump
Performance of
Hydraulic pump
See next page l/min See next page
delivery
10 PC400, 450-7E0
PC400, 400LC-7E0
Applicable model
PC450, 450LC-7E0
Cate- Permissible
Item Measurement Condition Unit Standard value
gory value
Discharge amount of hydraulic pump (P mode)

Performance of hydraulic pump
• Pump speed: At 1,950 rpm, PC current 280 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (l/min) (l/min)
As desired P1 P2 P1+P2 See graph See graph

2
a 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.
a 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
Standard value table for chassis related parts

(Loading shovel specification) 1
Applicable model PC400-7E0
Cate-
gory
2 pumps at relief 1,930 ± 100 1,930 ± 100
• Arm in relief condition
Engine speed

At 2-pump relief + one rpm
Within operating range 1,830 ± 100 1,830 ± 100
touch power up
• Arm relief + power max. switch
in ON condition
Speed when auto- • Auto-deceleration switch in ON
deceleration is oper- condition 1,300 ± 100 1,300 ± 100
ated • All control levers in NEUTRAL
condition
Boom control valve l l a b l a b
a b
Spool stroke
Arm control valve
Bucket control valve mm 9.5 ± 9.5 ± 9.5 ± 9.5 ±

— —
Swing control valve 0.5 0.5 0.5 0.5
Travel control valve BLP00101
Max. 95
Boom control lever 85 ± 10
Min. 75
Max. 95
Travel of control levers
Arm control lever 85 ± 10

Min. 75
• Engine stopped Max. 95
Bucket control lever 85 ± 10
• At center of control lever grip Min. 75
• Max. reading up to stroke end mm
Max. 95
Swing control lever (excepting lever play in NEU- 85 ± 10
Min. 75
TRAL position)
Max. 127
Travel control lever 115 ± 12
Min. 103
Work equipment,
Play of control levers Max. 10 Max. 15
swing
15.68 ± 3.92 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.5}
Operating effort of control levers
15.68 ± 3.92 Max. 24.5

Arm control lever
• Hydraulic oil temperature: {1.6 ± 0.4} {Max. 2.5}
Within operation range 12.74 ± 2.94 Max. 21.56
Bucket control lever • Engine at high idle {1.3 ± 0.3} {Max. 2.2}
• Hydraulic oil temperature: N {kg}
Within operating range 12.74 ± 2.94 Max. 21.56
Swing control lever
• At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end 24.5 ± 5.88 Max. 39.2
Lever
Travel {2.5 ± 0.6} {Max. 4.0}
control 74.48 ± 18.62 Max. 107.8
Pedal
{7.6 ± 1.9} {Max. 11}
12 PC400, 450-7E0
Cate-
gory
4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Working mode: P mode
{42 ± 10} {42 ± 10}
• Hydraulic pump output pressure
with all control levers in NEU-
TRAL position
33.83 – 36.28 33.34 – 36.77
RAISE
{345 – 370} {340 – 375}
At low- 30.9 – 33.8 33.38 – 34.3
Boom pressure
LOWER
setting {315 – 345} {310 – 350}
At high- 17.1 – 20.5 16.66 – 21.07
pressure
setting {175 – 210} {170 – 215}
31.8 – 34.3 31.36 – 34.79
IN
• Oil temperature: {325 – 350} {320 – 355}
Arm 45 – 55°C
31.8 – 34.3 31.36 – 34.79
• Engine at full throttle OUT
{325 – 350} {320 – 355}
• In heavy duty mode
• Pump outlet port 32.3 – 34.79 31.85 – 35.28
CURL
pressure {330 – 355} {325 – 355}
Bucket • Relive only circuit 31.8 – 34.3 31.36 – 34.79
being measured DUMP
{325 – 350} {320 – 355}
Hydraulic pressure
31.8 – 34.3 31.36 – 34.79

OPEN
{325 – 350} {320 – 355}
Bottom dump
MPa 29.9 – 33.3 29.4 – 33.81
CLOSE {kg/cm2}
{305 – 340} {300 – 345}
30.89 +1.47
–2.45 27.95 – 32.85
Swing
{315 +15
–25 }
{285 – 335}
37.27 +2.94
–0.98 35.79 – 40.70
Travel
{380 +30
–10 }
{365 – 415}
Control circuit source • Engine at high idle 3.24 ± 0.2 2.84 – 3.43
pressure • Self pressure reducing valve {33 ± 2} {29 – 35}
output pressure with all control
levers in NEUTRAL position
• Hydraulic oil tem- When all

perature: Within control levers 4.2 ± 1.0 4.2 ± 1.0
operation range in NEUTRAL {42 ± 10} {42 ± 10}
• Engine at high idle position
• Working mode: P
LS differential pressure
mode
• Traveling speed: Hi When travel-
• Hydraulic oil ing at half 2.65 ± 0.1 2.65 ± 0.1
pump pressure – stroke {27 ± 1} {27 ± 1}
LS pressure (without load)

PPC valve output Within operation range 2.9 +0.6
–0.2 2.9 +0.6
–0.2
pressure • Engine at high idle {30 +5.5
–1.5 } {30 +5.5
–1.5 }
• Control lever full stroke
PC400, 450-7E0 13
Cate-
gory
Work equipment posture: Max. reach
Overrun when stopping

deg. 120 150
swing • Engine at full throttle
45 – 55°C
• In H/O mode
• Stop after swinging one turn and
measure distance that swing cir-
cuit moves
Work equipment posture:
Max. reach
90° 3.7 ± 0.4 Max. 4.6
Time taken to start

sec.
swing
• Engine at full throttle
45 – 55°C 180° 5.4 ± 0.5 Max. 6.4
• In H/O mode
• Time taken to swing 90° and
180° from starting position
Work equipment posture: Max. reach
Swing
Time taken to swing sec. 33.7 ± 1.7 Max. 38

45 – 55°C
• In H/O mode
• Swing one turn, then measure
time taken to swing next 5 turns
Hydraulic drift of swing • Engine stopped mm 0 0

45 – 55°C
• Set machine on 15° slope, and
set upper structure at 90° to the
side
• Make match marks on swing cir-
cle outer race and track frame
• Measure distance that match
marks move apart after 5 minutes
14 PC400, 450-7E0
Cate-
gory
Swing
Leakage from swing

45 – 55°C l/min Max. 5.5 Max. 11
motor
• Swing lock switch ON
• Relieve swing circuit
Lo 63.2 ± 12.6 42.0 – 80.0
Travel speed
• Hydraulic oil temperature: Mi sec. 45.1 ± 6.8 31.5 – 55.0
(Idle travel)
• Time required for track shoes
Hi 34.5 ± 3.5 48.0 – 41.5
to make 5 turns after making
one initial idle turn
Lo 24.0 ± 4.8 18.9 – 31.0
Travel speed
Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel)
Travel
• Flat ground Hi 13.1 – 1.3 11.7 – 15.1

• Time required for traveling
20 m after 10 m trial run

45 – 55°C
• Travel speed: Hi
Travel deviation • Run up for at least 10 m, and mm Max. 200 Max. 300
measure deviation when traveling
next 20 m on flat ground
a Use a hard flat ground
a Measure dimension (χ)
PC400, 450-7E0 15
Cate-
gory
Hydraulic drift of travel • Engine stopped mm 0 0

45 – 55°C
• Stop machine on 12° slope with
sprocket facing straight up the
slope
• Measure the distance that
Travel
machine moves in 5 minutes
Leakage of travel
l/min Max. 20 Max. 40
motor
• Fit lock pin (1)
45 – 55°C
• Lock shoes and relieve travel cir-
cuit
Posture for measurement
Whole work
equipment (tooth Max. 600 Max. 900
tip fall amount)
Hydraulic drift of work equipment
Boom cylinder • Place in above posture and mea-

(cylinder retraction sure extension or retraction of Max. 25 Max. 38
Work equipment
amount) each cylinder and downward

movement at tip of bucket teeth
• Bucket: mm
Rated load 21.2 kN {2,160 kg}
Arm cylinder • Horizontal flat ground
(cylinder extension • Levers at neutral Max. 85 Max. 128
amount) • Engine stopped
45 – 55°C
• Start measuring immediately after
Bucket cylinder setting
(cylinder retraction • Measure hydraulic drift every 5 Max. 30 Max. 45
amount) minutes, and judge from results
for 15 minutes
16 PC400, 450-7E0
Cate-
gory
Boom
RAISE
4.7 ± 0.5 Max. 5.7
Bucket teeth in
contact with ground
LOWER
Cylinder fully • Hydraulic oil temperature: 3.7 ± 0.4 Max. 4.5
extended 45 – 55°C
• In A mode
Arm
CURL
2.6 ± 0.3 Max. 3.2
Cylinder fully
retracted

Work equipment speed
DUMP
Fully extended • Hydraulic oil temperature: 3.7 ± 0.4 Max. 4.5
Work equipment
45 – 55°C
• In A mode
sec.
Bucket
CURL
5.2 ± 0.6 Max. 6.4

Cylinder fully
retracted

DUMP
Fully extended
• Hydraulic oil temperature: 3.5 ± 0.4 Max. 4.3
45 – 55°C
• In A mode
Bottom dump
OPEN
1.9 ± 0.2 Max. 2.3

Cylinder fully
retracted

CLOSE
Fully extended • Hydraulic oil temperature: 2.1 ± 0.3 Max. 2.7

45 – 55°C
• In A mode
PC400, 450-7E0 17
Cate-
gory
Boom 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
• Hydraulic temperature: 45 – 55°C
Arm Max. 3.0 Max. 5.0

• Stop arm suddenly and measure
time taken for arm to stop
45 – 55°C
Work equipment
Time lag
sec.
Bucket Max. 3.0 Max. 5.0
• Stop bucket suddenly and mea-

sure time taken for bucket to stop
at bottom and then start again
45 – 55°C
Bottom dump Max. 3.0 Max. 5.0

• Time taken for bottom dump to
move again when operated from
max. bottom open position to
close position and stopped tem-
porarily
45 – 55°C
18 PC400, 450-7E0
Cate-
gory
Internal leakage
Cylinders Max. 4.5 Max. 20

equipment

Work
45 – 55°C cc/
• Engine full throttle min
Center swivel joint • Relieve circuit to be measured Max. 10 Max. 50

45 – 55°C
aUse a hard flat ground
compound operation
aMeasure dimension (χ)

Performance in
Swerving amount in
simultaneous operation
mm Max. 400 Max. 440
at work equipment and
travel
• Oil temperature: 45 – 55°C

hydraulic pump
Performance of
Piston pump
Hydraulic pump
See next page l/min See next page
delivery
PC400, 450-7E0 19
Cate-
gory
Discharge amount of hydraulic pump (P mode)

Performance of hydraulic pump
• Pump speed: At 1,950 rpm, PC current 280 mA
Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (l/min) (l/min)
As desired P1 P2 P1+P2 See graph See graph

2
a 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.
a 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.
20 PC400, 450-7E0
PC400, 450-7E0 21
SEN03595-02

© 2009 KOMATSU
All Rights Reserved
22
SEN03597-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
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 1
SEN03597-02 30 Testing and adjusting
Bleeding air from fuel circuit.......................................................................................................................... 24

Checking fuel circuit for leakage ................................................................................................................... 26
Checking and adjusting fan belt and alternator belt tension ......................................................................... 27
Checking and adjusting air conditioner compressor belt tension .................................................................. 28
Measuring swing circle bearing clearance .................................................................................................... 29
Checking and adjusting track shoe tension................................................................................................... 30
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................................... 31
Measuring control circuit basic pressure....................................................................................................... 35
Checking and adjusting pump PC control circuit oil pressure ....................................................................... 36
Checking and adjusting pump LS control circuit oil pressure........................................................................ 39
Measuring solenoid valve output pressure.................................................................................................... 44
Measuring PPC valve output pressure.......................................................................................................... 47
Adjusting play of work equipment and swing PPC valves............................................................................. 48
Inspecting locations of hydraulic drift of work equipment.............................................................................. 49
Releasing residual pressure from hydraulic circuit........................................................................................ 51
Measuring oil leakage amount ...................................................................................................................... 52
Bleeding air from various parts ..................................................................................................................... 55
2 PC400, 450-7E0
30 Testing and adjusting SEN03597-02
Tools for testing, adjusting and troubleshooting 1
Testing and adjusting Sym-

Part No. Part name Q'ty Remarks
item bol
Measuring intake air pres- –101 – 200 kPa { –760 – 1,500
A 799-201-2202 Boost gauge kit 1
sure (boost pressure) mmHg}
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
C Commercially
color 2 Smoke meter 1
available
Commercially
Adjusting valve clearance D Clearance gauge 1
available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1420 Adapter 1
pressure 2 For 125E-5 engine
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
Measuring engine oil pres- 1 {25, 60, 400, 600 kg/cm2}
G
sure 790-261-1204 Digital hydraulic tester 1 Pressure gauge:60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge:1 MPa {10 kg/cm2}
Measuring EGR valve drive 799-101-5002 Hydraulic tester 1
U * Common with G1
pressure 790-261-1204 Digital hydraulic tester 1
Pressure gauge: 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel pressure H
790-261-1204 Digital hydraulic tester 1 Pressure gauge:60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint inside diameter: 10 mm
Commercially
3 Hose 1 Ø5 mm × 2 – 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 Ø15 mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring swing circle Commercially
K Dial gauge 1 With magnet
bearing clearance available
Measuring and adjusting oil 1 * Common with G1
790-261-1204 Digital hydraulic tester 1
pressure in work equipment, L
swing, and travel circuits 799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2
1 * Common with G1
Measuring and adjusting 790-261-1204 Digital hydraulic tester 1
M
control circuit voltage 799-101-5220 Nipple 2
2 * Common with L2
07002-11023 O-ring 2
PC400, 450-7E0 3

item bol
Measuring and adjusting oil 1 * Common with G1
pressure in pump PC con- N
trol circuit 799-101-5220 Nipple 4
2 * Common with L2
07002-11023 O-ring 4
1 * Common with G1
Measuring and adjusting oil
799-101-5220 Nipple 4
pressure in pump LS control O 2 * Common with L2
circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
1 * Common with G1
Measuring solenoid valve 799-401-3100 Adapter 1 Size: 02
P 2
output pressure 02896-11008 O-ring 1
799-401-3200 Adapter 1 Size: 03
3
02896-11009 O-ring 1
Measuring PPC valve out- 1 * Common with G1
Q 790-261-1204 Digital hydraulic tester 1
put pressure
2 799-301-1740 Joint 1 Size: PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
799-601-4101
or T-adapter assembly 1
799-601-4201
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
799-601-4180 • T-adapter 1 For EGR gas sensor
For controller (50-pole)
799-601-4211 • T-adapter 1
(Except 799-601-4201)
For controller (60-pole)
799-601-4220 • T-adapter 1
(Except 799-601-4201)
Troubleshooting for/engine 799-601-4240 • Socket 1 For ambient pressure sensor
S
controller/sensors/actuators
799-601-4250 • Socket 1 For boost pressure sensor
799-601-4260 • T-adapter 1 For controller (4-pole)
799-601-4330 • Socket 1 For Bkup sensor
For 60-pole type
799-601-4350 • T-box 1
(Except 799-601-4201)
For coolant temperature sensor
795-799-5530 • T-adapter 1
For fuel temperature sensor
795-799-5540 • T-adapter 1 For boost temperature sensor
799-601-9420 • T-adapter 1 For common rail pressure sensor
799-601-9430 • T-adapter 1 For supply pump PCV
4 PC400, 450-7E0

item bol
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
For EGR valve solenoid
799-601-9020 • T-adapter 1 For bypass valve solenoid
For injector
Troubleshooting for/engine For EGR valve stroke sensor
S
controller/sensors/actuators For bypass valve stroke sensor
799-601-9030 • T-adapter 1
(Except 799-601-4101 and 799-
601-4201)
799-601-9000
or
799-601-9100 T-adapter assembly 1
or
799-601-9300
799-601-9310 • Plate 1
For 24-pole type
799-601-9320 • T-box 1
799-601-2500
or
799-601-2700
or
799-601-2800
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 • T-adapter box 1 For econo (Except 799-601-2700)
799-601-2740 • Adapter for MIC 1 For MIC-5P
799-601-4101
or
799-601-4201
Troubleshooting for chassis/
T 799-601-9000
sensors/wiring harnesses
or
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
For AMP3P (Except 799-601-9000
799-601-9420 • Adapter for AMP 1
and 799-601-9200)
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For X1P (Except 799-601-7000 and
799-601-7010 • Adapter for X 1
799-601-7100)
799-601-7020 • Adapter for X 1 For X2P
PC400, 450-7E0 5

item bol
799-601-7040 • Adapter for X 1 For X4P
799-601-7050 • Adapter for SWP 1 For SW6P (Except 799-601-8000)
799-601-7060 • Adapter for SWP 1 For SW8P (Except 799-601-8000)
For SW14P (Except 799-601-7000
799-601-7070 • Adapter for SWP 1
and 799-601-7100)
For M1P (Except 799-601-7000
799-601-7080 • Adapter for M 1
and 799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7140 • Adapter for S 1 For S8P
For S12P (Blue) (Except 799-601-
799-601-7160 • Adapter for S 1
8000)
799-601-7170 • Adapter for S 1 For S16P (Blue)
Troubleshooting for chassis/ 799-601-7210 • Adapter for AMP040 1 For A16P

T
sensors/wiring harnesses 799-601-7220 • Adapter for AMP040 1 For A20P
799-601-7520 • Adapter for 070 1 For 070-12P
799-601-9000
799-601-9200
799-601-9110 • Adapter for DT (GR) 1 For DT12P (Gray)
799-601-9350 • Adapter for DRC 1 For DRC40P
799-601-9360 • Adapter for DRC 1 For DRC24P
Out of kit (No assembly No.)
799-601-7320 T-adapter for SWP 1 For AW16P
799-601-7340 T-adapter for M 1 For M8P
799-601-7360 T-adapter for relay 1 For REL-5P
799-601-7370 T-adapter for relay 1 For REL-6P
Measuring wear on sprocket — 796-627-1120 Wear gauge 1
Measuring coolant tempera-
— 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work equipment Commercially
— Stopwatch 1
speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
6 PC400, 450-7E0
Measuring engine speed 1 4) Measuring the engine speed when 2

pumps are relieved and power maximizing
1. Turn on the starter switch and then switch the is turned on (near the rated speed):
machine monitor display to “Monitoring”. 1] Start the engine and set the fuel dial
a For the operating method of the machine to the high idle (MAX) position.
monitor, see “Special functions of machine 2] Set the working mode switch to P-
monitor”. mode.
a Monitoring code: 01002 Engine speed 3] Put the arm in IN relief position and
01006 Engine speed keep the power max. switch
a Code 01002 represents the engine con- depressed.
troller information and code 01006 repre- a The power maximizing function is
sents the pump controller information. reset automatically in about 8.5 sec-
Either of the codes is usable for the mea- onds even if the switch is being
surement. depressed. Thus measurement of the
a Engine speed is indicated in multiple of 1 engine speed must be completed
r/min (1 rpm). within that period.
5) Measuring the speed when the auto-
decelerator is in operation:
1] Start the engine and set the fuel dial
to the high idle (MAX) position.
2] Turn on the auto-deceleration switch.
3] Set the work equipment, swing and
travel levers to the neutral position.
a The engine speed will be slowed
down to a certain level in about 5 sec-
onds from setting all levers in neutral.
This level is the engine speed when
operation of the auto-deceleration is
turned on.
2. Start the engine and keep it running until tem-

perature of the engine coolant and hydraulic oil
rise to the operating range.
3. Measure the engine speed under the respec-

tive conditions listed below.
1) RPM at low idle:
to the low idle (MIN) position.
2) RPM at high idle:
2] Set the working mode switch to P-
mode.
3] Turn off the auto-deceleration switch.
3) Measuring the engine speed when 2-
pumps are relieved:
2] Set the working mode switch to P-
mode.
3] Put the arm in the IN relief position.
PC400, 450-7E0 7
Measuring air boost pressure 1 3. Run the engine at middle or higher speed and
drain oil from the hose.
a Air boost pressure measuring tools a When draining the oil, open the self seal of
Symbol Part No. Part name the hose by inserting approximately half of
the gauge and hose connection. Repeat
A 799-201-2202 Boost gauge kit
operation until the oil is drained out.
a Be careful not to touch any hot part of the a If Pm kit (A) is available, the air-bleeding
engine when removing or installing the mea- coupling (790-261-1130) in that kit may be
surement tools. used.
a If oil is left in the hose, the gauge does not
1. Open the inspection cover of the engine hood work. Accordingly, be sure to drain the oil.
and remove intake air measuring plug (1).
a The plug removed can be any of the plug 4. Start the engine and keep it running until tem-
provided on the right and left side. perature of the engine coolant and hydraulic oil
5. Set the working mode switch to P-mode.
6. Measure the intake air pressure (boost pres-

sure) when the engine is set to high idle and
the boom RAISE side is relieved.
2. Install nipple [1] of the boost gauge kit A and

connect gauge [2] to it.
7. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
8 PC400, 450-7E0
Measuring exhaust temperature 1 5. A procedure of measuring periodical exhaust

temperature for preventive maintenance ser-
a Measuring tools for exhaust temperature vices (Pm clinic)
Symbol Part No. Part name 1) Set the working mode switch to P-mode.
2) Measure the exhaust temperature when
B 799-101-1502 Digital thermometer
the engine is set to high idle and the arm
k Before installing or removing the measur- IN side is relieved.
ing tools, make sure the manifold tempera- a Measure and record the exhaust tempera-
ture is sufficiently low. ture after making sure it is stabilized.
1. 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.

4. A procedure of measuring the maximum in

troubleshooting
Measurement of the maximum exhaust tem-
perature must be done under actual working
conditions.
a PEAK mode of the digital thermometer
shall be used.
PC400, 450-7E0 9
Measuring exhaust gas color 1

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

parts, while removing and installing a mea-
surement tool.
a 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. 2) Connect the probe hose, accelerator switch
outlet and air hose to the smoke meter C2.
1. Measurement with Handy Smoke Checker C1 a Keep the pressure of the supplied com-
1) Fit a filtering paper to Handy Smoke pressed air at 1.5 MPa {15 kg/cm2} or
Checker C1. below.
2) Insert the exhaust gas intake port to 3) Connect the power cable to an AC receptacle.
exhaust pipe (1). a Confirm that the smoke meter power
3) Start the engine and keep it running until switch is in the OFF position, before
the engine coolant temperature rises to connecting the power cable to an outlet.
the operating range. 4) Loosen the cap nut of the suction pump
4) Start the engine and accelerate it sud- and fit in the filter paper.
denly or run it at high idle and then oper- a Fit the filtering paper securely so that
ate the lever of smoke checker C1 in order air may not leak.
to suction exhaust gas to the filter paper. 5) Move the Smoke Meter C2 power switch
to the ON position.
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Let the exhaust gas stay on the filtering
machine is back to normal condition. paper by depressing the accelerator pedal of
Smoke Meter C2, when the engine speed is
2. Measurement with Smoke Meter C2 suddenly accelerated or kept at high idle.
1) Insert probe [1] of smoke meter C2 to the 8) Put the polluted filtering paper on non-pol-
outlet of exhaust pipe (1) and fix it to the luted filtering paper (more than 10 sheets)
exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
10 PC400, 450-7E0
Adjusting valve clearance 1

a Valve clearance adjustment tools
Commercially
D Clearance gauge
available
1. Open the inspection cover of the engine hood

and remove the head cover (1) of every cylin-
der.
a As for No.1 and 2 cylinders, remove the
air intake connector on the head cover,
too.
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.
2. Remove the belt protection covers (two cov-

ers) and then loosen the tension of the fan belt
and alternator belt.
a The belts are loosened for confirming the
timing mark. 6. Insert clearance gauge D in the clearance
between rocker arm (5) and crosshead (6) and
3. Remove radiator under cover. adjust the valve clearance with adjustment
screw (3).
4. Rotate the crankshaft forward to bring the a With the clearance gauge being inserted,
stamped “1.6 TOP” line (a) of the damper to turn the adjustment screw until it allows
pointer (2) and set the No. 1 cylinder to the the clearance gauge to move slightly.
compression top dead center.
a Crank the crank shaft using the crank pul-
ley mounting bolt (Bolt width: 24 mm). In
this case, turn the bolt in the normal rota-
tion 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 11
7. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
a It is also allowed to adjust respective cylin-

ders in the firing order by turning the crank
shaft 120° at a time.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. 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 “Test-
ing and adjusting fan belt and alternator
belt tension”.
12 PC400, 450-7E0
Measuring compression pressure1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Compression pressure measurement tools (Do not pry the injector top up).
1 795-502-1590 Compression gauge
E 795-471-1420 Adapter
2
6217-71-6112 Gasket
k Be careful not to get burnt by touching the

exhaust manifold or muffler, or get caught
with a rotating parts, while taking measure-
ment of compression pressure.
a Before measuring the compression pressure,
make sure the engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Run the engine for warm up until the engine oil 5. Install adapter E2 to the injector mounting hole
reaches 40 – 60°C. and connect compression gauge E1 to it.
a Fit the gasket to the adapter end without
2. Open the inspection cover of the engine hood fail.
and remove the head cover (1) of the cylinder a Fix the adapter with the injector holder.
to be tested. 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”.
3. Bring the cylinder to be tested to the compres-

sion top dead center and remove rocker arm
assembly (2).
a See “Adjusting valve clearance”.
4. Disconnect fuel high-pressure tube (3) and injec-

tor wiring harness (4) and remove injector (5).
a Before disconnecting the fuel high-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing 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 13
7. Referencing “Special functions of machine 3 Rocker arm assembly mounting

monitor”, set the no injection cranking and the bolt:
engine speed measurement mode. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see “Adjusting valve clear-
set the engine in this mode. ance”.
8. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
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 tempo-
rarily assemble them as a unit to the cylin-
der 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 pip-
ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
14 PC400, 450-7E0
Measuring blow-by pressure 1

a Blow-by pressure measurement tools
.

F 799-201-1504 Blow-by checker
1. Remove the engine under cover (1).
2. Install nozzle [1] of blow-by checker F to blow-

by hose (1) and connect it to gauge [2] using
the hose.

4. Measure the blow-by pressure under the fol-

lowing 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.

PC400, 450-7E0 15
Measuring engine oil pressure 1 4. Run the engine until the engine coolant is
heated up to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part name 5. Measure the engine oil pressure at low idle
and also at high idle.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge

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 con-

nect it to gauge G2.
16 PC400, 450-7E0
Measuring EGR valve and bypass 3. Connect hydraulic tester [1] to the nipple.
valve drive pressure 1
4. Start the engine and measure the oil pressure
a Measuring instruments for EGR valve and at low idle and high idle.
bypass valve drive pressure

U
790-261-1204 Digital hydraulic tester
a 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.
5. After finishing measurement, remove the mea-
q Remove the belt cover.
suring instruments and return the removed
q Remove the air conditioner compressor
parts.
belt.
q Replace the removed plug (07043-70211)
q Move the air conditioner compressor so
with new one. When reusing it, remove
that it will not be an obstacle to the work.
the sticking gasket sealant from it with a
wire brush and apply new adhesive or
2. Install nipple (Component of tool U: 790-301-
gasket sealant to it before installing.
2 Plug: LT-2 or LG-6
1190) to the oil pressure pickup hole.
3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
PC400, 450-7E0 17
Handling fuel system parts 1 Releasing residual pressure from

fuel system 1
a Precautions for checking and maintaining fuel
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for-
eign matter enters this system, it can cause a Low-pressure circuit: Between Feed pump –
trouble. Fuel filter – Fuel supply
When checking and maintaining the fuel sys- pump
tem, take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly High-pressure circuit: Between Fuel supply
with clean fuel. pump – Common rail –
a Precautions for replacing fuel filter cartridge Fuel injector
Be sure to use the Komatsu genuine fuel filter a The pressure in both low-pressure circuit and
cartridge. high-pressure circuit lowers to a safety level
Since the common rail fuel injection system automatically 30 seconds after the engine is
(CRI) consists of more precise parts than the stopped.
conventional fuel injection pump and nozzle, it a Before checking the fuel system and installing
employs a high-efficiency special filter to pre- and removing its parts, the residual pressure in
vent foreign matter from entering it. the fuel system must be released completely.
If a filter other than the genuine one is used, Accordingly, observe the following.
the fuel system may have a trouble. Accord- k Before checking the fuel system, or install-
ingly, never use such a filter. ing 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.)
18 PC400, 450-7E0
Measuring fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
H 790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install nipple [1] (R1/8) and hydraulic tester H1

and connect them to gauge H2.
PC400, 450-7E0 19
Handling during cylinder cut-out Handling during no injection

operation 1 cranking operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no-injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When a cylinder is selected for the reduced a See the section of “Special functions of
cylinder mode operation, if the engine speed machine monitor” when turning on the no injec-
and output do not change from the normal tion cranking operation.
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
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder 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 cyl-
inder cut-out operation.
20 PC400, 450-7E0
Measuring fuel return rate and leakage 1
a Testing tools for leakage from pressure limiter 1. Preparation work

and return rate from injector 1) Remove tube (3) between common rail (1)
and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2) 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.
3) 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.
PC400, 450-7E0 21
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) After finishing testing, stop the engine.
3. 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 injec-
tor.
a Disconnect both ends of the injector.
1) Disconnect fuel return hose (4) of return
2. Testing leakage from pressure limiter block (2).
1) Adjust routing to prevent its slacking of a Place a plug on the fuel hose side
inspection hose J3 and insert the hose and then fix it to the fuel tank.
end to the oil pan (saucer). Plug: 07376-70315
2) Referencing “Measuring engine speed”,
set up the condition necessary for check-
ing 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 lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
2) Connect inspection hose J4 to return
1,600 Max. 10 block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
22 PC400, 450-7E0
3) Adjust routing to prevent its slacking of

inspection hose J4 and insert the hose
end to the oil pan (container).
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
4) Referencing “Measuring engine speed”, tools and return the removed parts.
set up the condition necessary for check-
ing the engine speed.
5) Run the engine at the rated output.
6) 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 injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
PC400, 450-7E0 23
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
1. Remove fuel pre-fuel filter (1) and fill it with

fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) exter-
nally.
24 PC400, 450-7E0
2. Install pre-fuel filter (1) to the filter head. 5. Loosen air bleeder (6) of the fuel supply pump
a Apply engine oil thinly over the packing on and operate lever (7) of priming pump (4) 90 –
the pre-fuel filter side. 100 times.
a After the packing of the pre-fuel filter a Operate the priming pump until the fuel
touches the sealing face of the filter head, flows out of the air bleeder and tighten the
tighten the fuel filter 3/4 turns. air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
3. Remove air bleeding plug (4) of the fuel main

filter and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeding plug (5) of the fuel main fil-

ter (2) and operate lever (7) of priming pump
(4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
PC400, 450-7E0 25
Checking fuel circuit for leakage 1 8. Run the engine at high idle and load it.
a When testing the engine mounted on the
k Very high pressure is generated in the high- machine, stall the torque converter or
pressure circuit of the fuel system. If fuel relieve the oil pressure from the hydraulic
leaks while the engine is running, it is dan- pump.
gerous since it can catch fire.
After testing the fuel system or removing 9. Inspect the fuel piping and devices for fuel
its parts, test it for fuel leakage according leakage.
to the following procedure. a Inspect mainly around the high-pressure
a Clean and degrease the engine and the parts circuit parts coated with the color checker
around it in advance so that you can test it eas- for fuel leakage.
ily for fuel leakage. a If any fuel leakage is detected, repair it
and inspect again from step 1.
1. Spray color checker (developer) over the fuel a If no fuel leakage is detected, inspection is
supply pump, common rail, fuel injector, and completed.
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. 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 check again from step 1.
4. Run the engine at low idle.

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

leakage.
for fuel leakage.
26 PC400, 450-7E0
Checking and adjusting fan belt 4. Slide alternator (7) by rotating adjusting nut
and alternator belt tension 1 (6), adjust V belt (8) tension and tighten lock-
nut (5).
Checking a Nut (6):
1. Open the engine hood and remove the belt q Tightening the locknut clockwise
protection covers (2 covers). moves it to the belt-loosening side.
q Tightening the locknut counterclock-
2. Press the intermediate point of the belt wise moves it to the belt-tightening
between fan pulley and compressor pulley with side.
a finger and measure deflection (a) of the belt. a Check the pulleys for breakage, V-groove
a Deflection (a) when pressing force of for wear, V-belt for wear and contact of the
approx. 58.8 N {approx. 6 kg} is applied: V-belt and V-groove for any trouble.
13 – 16 mm 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).

3 Bolt (3): 107.8 – 147 Nm {11 – 15 kgm}
3 Bolt (4): 28.4 – 38.2 Nm {2.9 – 3.9 kgm}
a When a V-belt is replaced, adjust the ten-
sion again after operating the machine for
an hour.
Adjusting
a If the V belt deflection is abnormal, adjust it
according to the following procedure.

and remove the bracket (1) and cover (2).
2. Loosen mounting bolt (3) and fixing bolt (4).
3. Loosen locknut (5).
PC400, 450-7E0 27
Checking and adjusting air 2. Loosen mounting bolt (2) and fixing bolt (3).
conditioner compressor belt
3. Slide compressor (6) by loosening locknut (4)
tension 1 and rotating adjusting nut, adjust V-belt (7) ten-
Checking sion and tighten locknut (5).
1. Open the engine hood and remove the belt a Check the pulleys for breakage, V-groove
protection covers (2 covers). for wear, V-belt for wear and contact of the
V-belt and V-groove for any trouble.
2. Press the intermediate point of the belt between a A belt must be replaced with a new one
air compressor pulley and drive pulley with a fin- when it is elongated so as to eliminate the
ger and measure deflection (a) of the belt. adjustment allowance, or when cuts or
a Pressing force: Deflection (a) when press- cracks are visible on it.
ing force of approx. 58.8 N {approx. 6 kg} 4. Tighten mounting bolt (2) and fixing bolt (3).
is applied: 14 – 16 mm a When a V-belt is replaced, adjust the ten-
sion again after operating the machine for
an hour.
Adjusting
a If the belt deflection is abnormal, adjust it
and remove cover (1).
28 PC400, 450-7E0
Measuring swing circle bearing 3. Set dial gauge to the zero point.
clearance 1
a Swing circle bearing clearance measurement
tools
Commercially
K Dial gauge
available
a Follow the steps explained below when mea-

suring clearance in the swing circle bearing on
the actual machine.
k Be careful not to put a hand or foot under
the undercarriage, while taking measure- 4. Hold the arm nearly perpendicular to the
ment. ground, and lower the boom until the track
shoes will be lifted at the machine front.
1. Fix dial gauge K to outer lace (1) or inner lace a The upper structure is raised at the front
(2) of the swing circle and contact the probe and lowered at the rear at that time.
against the end face of inner lace (2) or outer
lace (1) on the opposite side. 5. From this state, read the dial gauge K value.
a Set dial gauge K in the front side or rear a The value indicated by dial gauge K is the
side of the machine. clearance of the bearing.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth 6. Return the machine to the condition of step 2
tip level with the lower height of the revolving and check that dial gauge K indicates zero
frame. point.
a The upper structure is lowered at the front a If zero value is not indicated, repeat the
and raised at the rear at that time. steps in Items 3 through 5.
PC400, 450-7E0 29
Checking and adjusting track Adjusting

shoe tension 1 a If the track shoe tension is not proper, adjust it
in the following manner.
Checking
1. Run the engine at low idle and drive the 1. When the tension is too strong
machine forward by the length of track on Loosen valve (3) to discharge the grease.
ground, and then stop slowly. k Do not loosen the valve more than 1
turn. Otherwise, the valve may jump
2. Place steel bar [1] on the track shoe between out because of th e high- pressure
the idler (1) and the 1st carrier roller (2). grease inside.
a L beam is recommended for bar [1]
because of its deflection-free nature. 2. When the tension is too weak
Add grease through valve (3).
3. Measure maximum clearance (a) between a If the normal track shoe tension is not
steel bar [1] and track shoe. restored even after greasing, move the
q Standard maximum clearance (a): 10 – 30 mm machine slowly back and forth.
30 PC400, 450-7E0
Measuring and adjusting oil

pressure in work equipment,
swing, and travel circuits 1
a Measuring and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equip-
ment, swing and travel
1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
a The oil pressure in the work equipment, swing, 2) Fit nipple L2 and connect it to oil pressure
and travel circuits can be checked with moni- gauge [1] of hydraulic tester L1.
toring function of the monitor panel, too (For a The oil pressure gauges used shall
details, see “Special functions of monitor be 60 MPa {600 kg/cm2}.
panel”).
q Monitoring code: 01100 F pump pressure
01101 R pump pressure
q Pump oil pressure is indicated in multiples of
1 MPa (1 kg/cm2, 1PSI).
3) Start the engine and keep it running until

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 (1): Front pump discharge pressure

measuring plug
q (2): Rear pump discharge pressure
measuring plug
PC400, 450-7E0 31
2. Combination of pump, actuator, and valve a Turning on the swing lock switch
a When the oil from the pumps is divided, always turns on the 2-stage relief
the front pump and rear pump act inde- solenoid valve, causing the high-pres-
pendently on each actuator. Note that dif- sure relief. Accordingly, keep the
ferent actuators relieve different valves. swing lock switch turned OFF.
a When the work equipment circuit or swing
circuit is relieved singly, the oil of the 5. Measurement of swing relief pressure
pumps is diverted. 1) Start the engine and move the swing lock
a The actuators in the table are arranged in switch to the ON position.
the order when the control valve is seen 2) Measure hydraulic oil pressure when the
from the front of the machine. engine is running at high idle and the
swing circuit is relieved.
Pump Actuator Valve relieved
a Hydraulic oil pressure when the swing
(F unload valve) (F main relief valve) motor safety valve is relieved is dis-
Service Safety valve for service played.
Boom Hi a The relief pressure of the swing motor
F main relief valve is lower than the main relief pressure.
Arm Hi
Front
Bucket F main relief valve
6. Measurement of travel circuit relief pressure
Left travel F main relief valve 1) Start the engine, and lock the travel.
Raise: F main relief valve k Insert pin [2] between the sprocket
Boom
Lower: Safety-suction valve and the track frame to positively
(Pump merge-divider valve) (Travel junction valve) lock the travel circuit.
(Self pressure reducing valve)
Swing Swing motor safety valve
Rear 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. 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. 2) Measure the pressure when the engine is
a Hydraulic oil pressure when the set to high idle and the travel circuit is
unload valve unloads is displayed. relieved.
a Hydraulic oil pressure with the main relief
4. Measurement of work equipment relief valve in relief condition is displayed. In
pressure the travel circuit relief, the pressure is
1) Start the engine and move the cylinder to high pressure relief all the time.
be measured to its stroke end. Adjusting
2) Measure hydraulic oil pressure when the a Adjustment of the unload valve is not available.
cylinder is relieved while the engine is run-
ning at high idle. 1. Adjustment of main relief pressure
a The pressure measured when the a When the relief pressure of the work
main relief valve is relieved is indi- equipment circuit or travel circuit is abnor-
cated. mal, adjust main relief valves (3) and (4)
a If the power maximizing switch is according to the following procedure.
released, the main relief valve is q (3): Front main relief valve
relieved at low pressure. If the former q (4): Rear main relief valve
is pressed, the latter is relieved at a When adjusting the main relief valve on
high pressure. the front pump side, remove the top cover
of the control valve.
32 PC400, 450-7E0
a When adjusting the main relief valve on 2. Adjustment of boom LOWER relief pressure
the rear pump side, remove the under (on the side where high pressure is set)
cover of the control valve (when it is a If the high relief pressure for boom
installed). LOWER is not normal, adjust the high
a As for the main relief valve, be sure to pressure set side of safety-suction valve
adjust its low-pressure relief pressure (8) for boom LOWER according to the fol-
alone (adjusting the low-pressure relief lowing procedure.
pressure automatically sets the high-pres- a The high-pressure relief pressure mode
sure relief pressure, too.). denotes the state in which the machine
a When the low-pressure relief pressure is push-up switch is turned on, disabling to
turned on, the 2-stage relief valve is OFF apply the pilot pressure to the switching
and thus the pilot pressure is not applica- port.
ble to the switching port.
1) Disconnect pilot hose (9).

2) While fixing holder (10), loosen locknut
1) Disconnect pilot hose (5).
(11).
2) While fixing holder (6), loosen locknut (7).
3) Turn holder (10) to adjust the pressure.
3) Turn holder (6) to adjust the pressure.
a Turning the holder clockwise increases
a Turning the holder clockwise increases
the pressure. Turning it counterclock-
the pressure. Turning it counterclock-
wise decreases the pressure.
wise decreases the pressure.
a Quantity of adjustment per turn of
a Quantity of adjustment per turn of
holder:
holder:
Approx. 25.3 MPa {Approx. 258 kg/cm2}
Approx. 20.5 MPa {Approx. 209 kg/cm2}
4) While fixing holder (10), tighten locknut
4) While fixing holder (6), tighten locknut (7).
3 Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}
(11).
3 Locknut:
93 – 123 Nm {9.5 – 12.5 kgm}
5) Connect pilot hose (5).

6) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement.
PC400, 450-7E0 33
5) Connect pilot hose (9). 4. Adjustment of swing relief pressure

6) Check the pressure again after the adjust- a If the swing relief pressure is abnormal,
ment, following the aforementioned steps adjust safety valve (14) of the swing motor
for measurement. according to the following procedure.
a Adjusting the high pressure set side
changes setting of the low pressure
side. Thus, this side requires adjust-
ment, too.
3. 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 fol-
lowing procedure.
a The low-pressure relief pressure mode
denotes the state in which the machine
push-up switch is turned off, disabling to 1) While fixing adjusting screw (15), loosen
apply the pilot pressure to the switching port. locknut (16).
1) Disconnect pilot hose (9). 2) Turn adjustment screw (15) to adjust the
2) While fixing holder (12), loosen locknut pressure.
(13). a Adjustment screw:
3) Turn holder (10) to adjust the pressure. q Turning it clockwise increases
a Turning the holder clockwise increases the pressure.
the pressure. Turning it counterclock- q Turning it counterclockwise
wise decreases the pressure. decreases the pressure.
a Quantity of adjustment per turn of a Quantity of adjustment per turn of
holder: adjusting screw:
Approx. 25.3 MPa {Approx. 258 kg/cm2} 4.70 MPa {47.9kg/cm2}
4) While fixing holder (12), tighten locknut 3) While fixing adjustment screw (15), tighten
(13). locknut (16).
3 Locknut 78 – 93 Nm {8.0 – 9.5 kgm} 3 Locknut:
147 – 196 Nm {15 – 20 kgm}
5) Connect pilot hose (9).

6) Check the pressure again after the adjust- 4) Check the pressure again after the adjust-
ment, following the aforementioned steps ment, following the aforementioned steps
for measurement. for measurement.
34 PC400, 450-7E0
Measuring control circuit basic 3. Start the engine and keep it running until the
pressure 1 hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure inspection and
adjustment tools 4. Measure hydraulic oil pressure, when the
Symbol Part No. Part name engine is running at high idle and all the control
levers are moved to the NEUTRAL position.
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
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 pres-
sure inside the tank.
1. Remove the top cover of the control valve and

remove plug (1) for measuring the control cir-
cuit basic pressure.
a The figure shows the control valve side
viewed from inside the pump room.
a It is not allowed to adjust the relief valve of
the control circuit source pressure.
2. 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 35
Checking and adjusting pump PC 2) Install nipple N2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauge with
a Pump PC control circuit oil pressure checking capacity 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
N
799-101-5220 Nipple (10 × 1.25 mm)
2
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.
q The figure shows the PC valve output
side.
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).
measuring plug
measuring plug
the hydraulic oil temperature rises to the
q (3): Front PC valve output pressure
operating range.
measuring plug
q (4): Rear PC valve output pressure
measuring plug
36 PC400, 450-7E0
4) Measure the pump discharge pressure 2) Install nipple N2 and connect it to oil pres-
and PC valve output pressure (pressure at sure gauge [1] of hydraulic tester N1.
servo piston inlet) at the same time after a The oil pressure gauges used shall
setting following conditions with the be 6 MPa {60 kg/cm2}.
engine running at high idle.
q Swing lock switch: ON
(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 pres-
sure and PC valve output pressure
(servo piston output pressure), the
PC valve is normal.
Measured oil
Oil pressure ratio
pressure
Pump discharge the hydraulic oil temperature rises to the
1
pressure
operating range.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a 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.
2. Measurement of PC-EPC valve output pressure

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

PC400, 450-7E0 37
Adjusting 3. Tighten locknut (8).

a If either of the following phenomena occurs 3 Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
and the PC valve seems to be defective, adjust

PC valves (6) and (7) according to the proce-
dure 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 adjust-
ment screw (inside width) is 4 mm. Do not
turn any other locknuts or adjustment
screws since they affects the hydraulic
pump performance. 4. After the adjustment, make sure that the PC
valve output pressure (servo piston inlet pres-
sure) is normal using the measurement steps
explained earlier.
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 posi-
tion after turning it in reverse).
2. Turn adjustment screw (9) clockwise or coun-

terclockwise 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 adjust-
ment available from the adjusting screw.
q Counterclockwise: Within 1 turn
q Clockwise: Within 1 turn
38 PC400, 450-7E0
Checking and adjusting pump LS 2) Install nipple O2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester O2.
a The oil pressure gauges used shall
a Pump LS control circuit oil pressure checking be 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
O 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
a Measurement of the oil pressure in the pump
LS control circuit shall be conducted after mak-
ing sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
and, after stopping the engine, release q The figure shows the LS valve output
residual pressure in the piping by operating side.
1. 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).
measuring plug
measuring plug 3) Run the engine until the hydraulic oil tem-
q (3): Front pump LS valve output perature reaches the operating range and
pressure measuring plug then push up the measurement side track
q (4): Rear pump LS valve output pres- shoe with the work equipment.
sure measuring plug q When measuring the front circuit:
Left track shoe
q When measuring the rear circuit:
Right track shoe
k Provide a working area of suffi-
cient space, as the raised track
shoe will be idly rotated.
PC400, 450-7E0 39
2. Measurement of LS differential pressure

a LS differential pressure can be obtained
by measuring the pump discharge pres-
sure and LS pressure (actuator load pres-
sure) at the same time and computing the
difference between the two pressures.
oil pressure measuring plugs (1), (2), (5)
and (6).
measuring plug
measuring plug
4) 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.
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 sur-
roundings for safety.
a Judgement method:
q (5): Front pump LS pressure measur-
When the ratio between the pump
ing plug
discharge pressure and LS valve out-
q (6): Rear pump LS pressure measur-
put pressure (servo piston output
ing plug
pressure) reaches the following val-
ues, both pressures are judged nor-
mal.
Oil pressure ratio
Measured oil Travel lever
pressure All levers
moved half-
at neutral
way
Pump discharge
Almost 1
pressure
same
LS valve output pressure Approx. 0.6

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 pres-
sure to the high pressure side (back
side) and LS pressure to the low
pressure side (bottom side).
T he differential press ure gauge
needs 12 DCV power. Thus connect a
battery to it.
40 PC400, 450-7E0
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 recon-
necting the same gauge.
q The figure shows the pump discharge
pressure side.
4) Measure the pump discharge pressure and

LS pressure (actuator load pressure) at the
same time after setting the following condi-
tions with the engine running at high idle.
q Travel speed: Hi
When all levers are at neutral and
when travel lever is at half stroke (one
q The figure shows the LS pressure side of travel is at idle)
side. a Let the raised track shoe idly rotate,
paying enough attention to the sur-
roundings for safety.
a Calculating LS differential pressure
(When the oil pressure gauge is
used):
LS differential pressure = Pump dis-
charge pressure – LS pressure
a If LS differential pressure is in the fol-
lowing conditions, it is judged normal.
LS differential
Operation of levers
pressure
Unload pressure
When all levers at neu-
(See “Standard
tral
value table”)
3) Run the engine until the hydraulic oil tem- Maximum LS
perature reaches the operating range and differential pres-
Travel lever moved
sure
then push up the measurement side track halfway (Travel at idle)
(See “Standard
shoe with the work equipment.
value table”)
q When measuring the front circuit:
Left track shoe
q When measuring the rear circuit:
Right track shoe
k Provide a working area of suffi-
cient space, as the raised track
shoe will be idly rotated.
PC400, 450-7E0 41
3. Measurement of LS-EPC valve output pressure 4) Measure the oil pressure when the engine
1) Open the pump room cover and remove is running at high idle and the travel speed
LS-EPC valve output measuring plug (7). switch and travel control lever are oper-
ated.
a If LS-EPC valve output pressure
changes to the following values, the
pressure is normal.
Travel
Travel lever Oil pressure
speed
Approx. 2.94 MPa
Lo Neutral
{Approx. 30 kg/cm2}
Fine travel
Hi lever control 0 MPa {0 kg/cm2}
(Note)
Note: Operate the travel control lever

slightly to the extent that the PPC oil
2) Install nipple O2 and connect it to oil pres- pressure switch is turned ON (Stop
sure gauge [1] of hydraulic tester O1. the operation short of starting the
a Use the oil pressure gauge with machine).
capacity 6 MPa {60 kg/cm2}. 5) Remove the measurement tool after the

operating range.
42 PC400, 450-7E0
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 lock-

nut (11).
2. Turn adjusting screw (10) to adjust the pres-

sure.
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 adjust-
ment screw (LS differential pressure):
1.3 MPa {13.3 kg/cm2}
3. After the adjustment, confirm that LS differen-

tial pressure is normal, following the steps for
measurement explained earlier.
PC400, 450-7E0 43
Measuring solenoid valve output 2. Install adapter P2 or P3 and connect the cur-
pressure 1 rently disconnected hose again.
a Solenoid valve output pressure measurement 3. Install nipple [1] of hydraulic tester P1 and con-
tools nect it to oil pressure gauge [2].
Symbol Part No. Part name a Use the oil pressure gauge with capacity 6
MPa {60 kg/cm2}.
1 a Figure shows the outlet hose of the 2-
790-261-1204 Digital hydraulic tester stage solenoid valve being installed with
799-401-3100 Adapter (Size 02) the measuring tool.
P 2
02896-11008 O-ring
799-401-3200 Adapter (Size 03)
3
02896-11009 O-ring
a Measure the solenoid valve output pressure

after confirming that the control circuit source
pressure is normal.
4. Start the engine and keep it running until the
1. Remove the control valve top cover and dis- hydraulic oil temperature rises to the operating
connect outlet hoses (1) to (7) of the target range.
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 con-
ducted on PPC valve side (back side of
operator's cab).
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed shifting solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve 5. Run the engine at high idle and operate the con-
7 PPC lock solenoid valve trol 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 func-
tions of machine monitor”.
44 PC400, 450-7E0
a When each output pressure shows the fol-

lowing values, it is judged normal.
Solenoid valve Output pressure
OFF (De-energized) 0 MPa {0 kg/cm2}
Almost the same pres-
sure as the control cir-
ON (Energized)
cuit basic pressure (See
“Standard values table”)

Table for functioning conditions – 2-stage relief solenoid valve

Opera-
Operating condition
tion
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
Signals other than the swing single are ON
P or E-mode is selected Left knob switch is ON
Swing single is ON
OFF
Other than above conditions
Table for functioning conditions – machine push up solenoid valve

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

Opera-
Operating condition
tion
All are OFF OFF
Work equipment, swing, and travel signals
Any one is ON ON
PC400, 450-7E0 45
Table for functioning conditions – Travel speed shifting solenoid valve

Opera-
Operating condition
tion
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
F or R pump pressure is at 32.3 MPa {330 kg/cm2} or
Travel speed switch is at Mi or Hi above
Travel signal is ON
F or R pump pressure is at 18.6 MPa {190 kg/cm2} or
below ON
Table for functioning conditions – Merge/divide solenoid valve

Opera-
Operating condition
tion
When B mode is
Service single ON
selected
Travel is operated single ON
2
F or R pump pressure is at 19.6 MPa {200 kg/cm }
When a L-mode is not or above
Work equip- selected F or R pump pressure is at 14.7 MPa {150 kg/cm2}
Travel single signal ment, swing, OFF
or below
is ON and service
singles are F or R pump pressure is at 16.7 MPa {170 kg/cm2}
ON
ON or above
When L mode is selected
F or R pump pressure is at 11.8 MPa {120 kg/cm2}
OFF
or below
2
Arm IN and bucket CURL F or R pump pressure is at 24.5 MPa {250 kg/cm } ON
Travel signal is Swing sig- PPC pressure are or above
OFF nal is OFF 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
Table for functioning conditions – Travel junction solenoid valve

Opera-
Operating condition
tion
Travel steering signal is ON
Travel lever is oper- F or R pump pressure is at 34.3 MPa {350 kg/cm2} ON
Travel steering signal is OFF ated singly or above
Other than above conditions OFF
Table for functioning conditions – PPC lock solenoid valve

Opera-
Operating condition
tion
Lock OFF
Work equipment lock lever
Free ON
46 PC400, 450-7E0
Measuring PPC valve output

pressure 1
a PPC valve output pressure measurement tools
1
Q 790-261-1204 Digital hydraulic tester
2 799-301-1740 Joint (PF1/4 + PT1/4)

sure inside the tank. 3. Connect nipple [1] of joint Q2 and hydraulic
tester Q1 and connect them to oil pressure
1. Remove the control valve top cover and the gauge [2].
operator cab under cover (front side). a Joint Q2 shall be used only when the mea-
surement is taken at the pressure sensor
2. Remove PPC hydraulic switch or PPC pres- installation position.
sure sensors (1) to (10) of the target circuit of a The oil pressure gauges used shall be 6
measurement. MPa {60 kg/cm2}.
a PPC pressure sensor for arm IN and a Figure shows the measuring tools being
bucket CURL detects errors in the electri- installed at the installation position of PPC
cal system as the starter switch is turned pressure sensor for arm IN circuit.
on when the connector is disconnected.
After removing the pressure sensor, con-
nect it to the connector again and then
clamp it to a nearby bracket.
Circuit to be mea- Circuit to be mea-
No. No.
sured sured
1 Boom RAISE (S06) 6 Bucket DUMP (S05)
2 Boom LOWER (S02) 7 Swing LEFT (S07)
3 Arm IN (S04) 8 Swing RIGHT (S03)
4 Arm OUT (S08) 9 Travel (S30)
5 Bucket CURL (S01) 10 Steering (S31)
4. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
PC400, 450-7E0 47
5. Measure the pressure when the engine is run- Adjusting play of work equipment
ning at high idle and the control lever of the cir- and swing PPC valves 1
cuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If the right and left work equipment levers have
a If PPC valve output pressure is at the level large play, adjust them according to the follow-
shown below, it is judged normal. ing procedure.
1. Remove the work equipment and swing PPC

Operation of levers Oil pressure
valve assembly.
Neutral 0 MPa {0 kg/cm2}
Almost the same pres- 2. Remove bellows (1).
sure as the control cir-
Stroke end
cuit basic pressure (See 3. Loosen locknut (2) and tighten disc (3) until it
“Standard values table”) touches the heads of 4 pistons (4).
a Do not move the piston at this time.
6. Remove the measurement tool after the mea- 4. Fix disc (3) and tighten locknut (2) to the speci-
surement, and make sure that the machine is fied torque.
back to normal condition. 3 Locknut: 69 – 88 Nm {7 – 9 kgm}
5. Install bellows (1).
6. Install the work equipment and swing PPC

valve assembly.
48 PC400, 450-7E0
Inspecting locations of hydraulic 2. Inspection of arm cylinder

drift of work equipment 1 1) Stop the arm cylinder at a position approx-
imately 100 mm in front of the IN stroke
a If hydraulic drift occurred on the work equip- end and then stop the engine.
ment (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 pos-
ture as when measuring hydraulic drift,
and stop the engine.
a Fill the bucket with earth or apply the
rated load to the bucket.
2) 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.
2) When inspecting the boom cylinder, shift a If pressure in the accumulator has
the boom control lever to RAISE side and dropped, run the engine for approx.
when inspecting the bucket cylinder, shift 10 seconds to charge the accumula-
the bucket control lever to CURL side. tor again.
q If, as the result, drifting speed
increases, failure on the cylinder [Reference] Reasons why the lowering
packing should be suspected. speed is increased by the above operation
q If the speed remains unchanged, fail- when the cylinder packing is the cause of
ure on the control valve should be the hydraulic drift:
suspected. 1) If the work equipment is set to the
a Operate the control lever with the above posture (holding pressure
engine starting switch in the ON posi- applied to the bottom end), the oil at
tion. the bottom end leaks to the head end.
a If pressure in the accumulator has However, the volume at the head end
dropped, run the engine for approx. is smaller than the volume at the bot-
10 seconds to charge the accumula- tom end by the volume of the rod end,
tor again. so the internal pressure at the head
end increases because of the oil flow-
ing 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 leak-
age). As the pressure is balanced, the
drifting speed is decreased.
PC400, 450-7E0 49
3) If the lever is then operated according

to the procedure given above, the cir-
cuit 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.
3. 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.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
a If the lock and free position cause any dif-
ference in the hydraulic drift volume, the
PPC valve is defective (internal failure).
50 PC400, 450-7E0
Releasing residual pressure from 3. Releasing residual pressure from swing

hydraulic circuit 1 motor circuit
a The residual pressure in the swing motor
1. Releasing residual pressure from hydrau- circuit can be released by performing the
lic tank same operation for “Releasing residual
k Since the hydraulic tank is enclosed pressure from hydraulic cylinder circuit”
and pressurized, release the residual (Operate the lever in the swing direction
pressure from it when removing a hose only, however).
or a plug connected to it.
1) Lower the work equipment to the ground 4. Releasing residual pressure from travel
in a stable position and stop the engine. motor circuit
2) Loosen oil filler cap (1) of the hydraulic a Since the control valve spool of the travel
tank gradually to release the air in the motor circuit is open, the pressure in this
tank. circuit can be released by performing the
same operation as that for “Releasing
residual pressure from hydraulic tank”.
2. Releasing residual pressure from hydrau-

lic 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 follow-
ing 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 51
Measuring oil leakage amount 1 k Release the residual pressure from

the piping on the arm cylinder
a Measuring tools for oil leakage head side. For details, see “Releas-
Symbol Part No. Part name ing residual pressure from hydrau-
lic circuit” (Operate the lever in the
Commercially
R Measuring cylinder arm IN direction only, however).
available
3) Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the
1. Measuring oil leakage from boom cylinder
1) Start the engine and keep it running until hose at the cylinder bottom end.
the hydraulic oil temperature rises to the a Use the following parts to block the
operating range. hose side.
2) Move the boom cylinder to the RAISE 07379-01044 (Flange #10)
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 cir-
cuit”. (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.
hose at the cylinder bottom end.
a Use the following parts to block the
hose side.
07379-01044 (Flange #10)
4) Run the engine at high idle and relieve the
arm circuit by moving the arm IN.
k Take care not to “move the arm OUT”.
5) Continue this condition for 30 seconds,
then measure the oil leakage amount for
one minute.
6) After the measurement, make sure that
the machine is back to normal condition.
3. Measurement of oil leakage amount from

bucket cylinder
operating range.
2) Move the bucket cylinder to the CURL
4) Run the engine at high idle and relieve the stroke end and stop the engine.
k Release the residual pressure from
boom circuit by raising the boom.
k Take care not to “lower the boom”.
the piping on the bucket cylinder head
5) Continue this condition for 30 seconds, side. For details, see “Releasing
then measure the oil leakage amount for residual pressure from hydraulic cir-
one minute. cuit” (Operate the lever in the bucket
6) After the measurement, make sure that CURL direction only, however).
the machine is back to normal condition. 3) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.
arm cylinder hose at the cylinder bottom end.
operating range.
2) Move the arm cylinder to the IN stroke end
52 PC400, 450-7E0
a Use the following parts to block the a Continue this condition for 30 sec-
hose side. onds, then measure the oil leakage
07379-01044 (Flange #10) amount for one minute.
a After measuring 1 time, swinging 180°,
and then measure again.

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.
4) Run the engine at high idle and relieve the

bucket circuit by curling the bucket.
k Take care not to “Dump the
bucket”.
5) Continue this condition for 30 seconds,
then measure the oil leakage amount for
one minute.

swing motor
3) Disconnect drain hose (5) of the travel
operating range.
motor and block the hose side with a plug.
2) Disconnect drain hose (4) and block the
hose side with plugs.
hose side.
07376-70522 (Plug #05)
hose side.
07376-70522 (Plug #05)
3) Turn the swing lock switch to the ON posi-

tion.
4) Run the engine at high idle, relieve the
swing circuit, and measure the oil leakage.
PC400, 450-7E0 53
4) 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 sec-
onds, 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.
54 PC400, 450-7E0
Bleeding air from various parts 1

Air bleeding items Air bleeding procedure
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air Bleeding air
from Starting level and
from cylin- from swing from travel
hydraulic engine starting
der motor motor
Contents of work pump work
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q o o o q
• Replacing and repairing hydraulic
pump q q q o o q
• Removing suction piping
• Replacing and repairing control
valve q q o o q
• Removing control valve piping
• Replacing and repairing cylinder
q q o o q
• Removing cylinder piping
• Replacing and repairing swing
motor q o q o q
• Removing swing motor piping
• Replacing and repairing travel
motor q o o q q
• Removing travel motor piping
• Replacing and repairing swivel joint
q o o o q
• Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. 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:
2. Starting engine
When running the engine after performing step
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
1, keep its speed at low idle for 10 minutes.
a When the drain hose was discon-
a If the engine coolant temperature is low
nected for above operation, connect it
and the automatic warm-up operation is
again after tightening the bleeder.
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 sec-
onds, and the automatic warm-up opera-
tion is reset).
PC400, 450-7E0 55
3. Bleeding air from hydraulic cylinder 5. Bleeding air from travel motor
a In case a cylinder is replaced with new 1) Take off the travel motor cover.
one, it is advised to bleed air from the new 2) Start the engine and run it at low idle.
one before mounting the work equipment. 3) Loosen bleeder (4) to make sure oil oozes
It is especially so with the boom cylinder, out.
because its rod does not extend to the 4) After making sure that the oil from bleeder
stroke end of LOWER side, after the work (4) is free from mixed air, tighten the
equipment is mounted. bleeder.
1) Start the engine and keep running at low 3 Air bleeder:
idle for 5 minutes. 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
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, per-
form 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.
5) Using the work equipment, lift the track
2) Loosen S port hose (3) gradually to make
shoe of one side.
sure oil oozes out through the S port hose.
k In this case, don't try to turn on the
6) Gradually run the lifted track shoe at idle
for approximately two minutes.
swing operation.
a Repeat the same for the opposite
3) When oil does not flow out, stop the
side track shoe.
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.
56 PC400, 450-7E0
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) 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 situ-
ated between H and L lines.
a If the oil level is below line L, it is
insufficient. Add oil.
PC400, 450-7E0 57
SEN03597-02

© 2008 KOMATSU
All Rights Reserved
58
SEN03598-01

2SHOP
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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

[2]: Figure input switch 2 [E]: Upward move switch
[3]: Figure input switch 3 [R]: Downward move switch
[4]: Figure input switch 4 [3]: Input confirmation switch
[5]: Figure input switch 5
2 PC400, 450-7E0
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 avail-
able from the serviceman's operations of the special switches.
This mode is used for special setting, testing, adjusting or troubleshooting.
Operator menu Service menu

1 Password input and setting function 16 Monitoring [01] function
2 KOMATSU logo display screen Function of abnor- Electrical systems
17
3 Check before starting function mality record [02] 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 func-
6 20 Function of phone number entry [05]
tion
7 Ordinary screen display function Mode with key ON
Display's brightness and contrast adjusting func-
8 Language
tion Function of default
21
E-mode adjustment and pump flow rate adjust- [06] Unit
9 ment function when breaker or attachment is
used With/Without attachment
10 Check of maintenance information function Pump absorption torque

Function of adjust-
22 Adjustment of flow to attach-
11 Service meter display function ment [07]
ment 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 3
Operation of operator menu and display (outline)
a This section introduces only the outline of the 3. Check before starting function
operator menu. For details on the contents and Check before starting screen is displayed for 2
operation steps of each menu, refer to the seconds succeeding to display of KOMATSU
operation and maintenance manual or the logo.
chapter of “Structure, function and mainte-
nance 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.
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.
2. KOMATSU logo display screen
KOMATSU logo is displayed for 2 seconds as
a password is entered (as a password is speci-
fied) or the starting switch is turned ON.
4 PC400, 450-7E0
5. Caution items display function 7. Ordinary screen display function

Succeeding display of the check before start- The ordinary display is turned on succeeding
ing scre en, an ap plica ble caution m ark to display of the check of working mode and
appears pointing a check before starting item travel speed screen.
on which a problem was found. a If the currently set working mode or travel
speed is changed or if setting of the auto-
deceleration 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 dis-
played only when the pre-heating opera-
tion is turned on.
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 set-
ting.
8. Display's brightness and contrast adjusting
function
The screen adjustment switches allow adjust-
ing the display brightness and contrast.
PC400, 450-7E0 5
9. E-mode adjustment, flow rate adjustment 10. Check of maintenance information function
function when breaker or attachment is The maintenance switch allows checking
used (for a machine equipped with breaker detailed information of the maintenance items
and attachment) (specified maintenance time and elapsed
The select switch allows adjusting E-mode and time). It also allows resetting after the mainte-
also adjusting the pump flow rate when the nance.
breaker or attachment is used. a Setting and resetting of the maintenance
a There are some differences between the function as well as setting of the mainte-
symbol mark of the breaker and attach- nance time is done from the service menu.
ment displayed on the screen as well as in
the messages displayed.
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)
6 PC400, 450-7E0
12. Check of display LCD function 13. Caution generation display function
Display of the display LCD can check by oper- If a caution is warned for a caution item, appli-
ating the following switches from the password cable symbol mark is displayed large for 2 sec-
input screen or ordinary screen. onds and then it remains on the screen in a
q Switch operation: [/] + [A] (Simultaneous smaller size until the trouble is eliminated.
operation)
a The entire LCD should come on, turning
the screen to white. The display is, there-
fore, acceptable if it is free from any black
spot.
a Operating any switch from the checkup
display restores the immediately preced-
ing screen.
PC400, 450-7E0 7
14. Action code display function

If a trouble occurs on the machine, an applica-
ble action code is automatically displayed
depending on the seriousness of the trouble in
order to alert the operator to take an appropri-
ate action.
a Operating any switch while an action code
is on the screen, switch the failure code
display screen (see Item 15).
a Action codes and actions requested to operator
Action code Failure mode Action

When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
E03 Swing brake system error Have inspection carried out immediately.
Engine controller power source error
Engine controller drive system circuit
E10 Have inspection carried out immediately.
error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection car-
E11
(Output reduced to protect engine) ried out immediately.
Operate machine to a safe posture and have inspection car-
E14 Throttle system error
ried out immediately.
Engine sensor (coolant temperature, fuel
Operations are possible, but have inspection carried out
E15 temperature and oil pressure) system
immediately.
error
Operate machine to a safe posture and have inspection car-
E0E Network error
ried out immediately.
8 PC400, 450-7E0
15. Failure code display function a The telephone mark and telephone num-
Operating any switch while an action code is ber are displayed only when the telephone
on the screen, sequentially displays the phone number is registered to the machine moni-
mark (if registered), phone number (if regis- tor.
tered) and failure code. Registration, correction or deletion of a
q Switching operation: (3) (keep the switch telephone number is done from the ser-
depressed) vice menu.
a The screen display sequentially changes a For detailed information of failure codes,
as shown below as long as the switch is see the failure codes table.
being depressed.
(1) Telephone symbol mark
(2) Telephone number
(3) Failure code
PC400, 450-7E0 9
Failure codes table

Action Device in
Failure code Trouble (Displayed on screen) Category of record
code charge
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low ENG Mechanical system
— B@BAZK Eng. Oil Level Low MON Mechanical system
— B@BCNS Eng. Water Overheat ENG Mechanical system
— B@BCZK Eng. Water Lvl Low MON Mechanical system
— 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
E15 CA221 Ambient Press Sens High Error ENG Electrical system
E15 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
E11 CA271 IMV/PCV1 Short Error 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
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E10 CA441 Battery Voltage Low Error ENG Electrical system
E10 CA442 Battery Voltage High Error ENG Electrical system
10 PC400, 450-7E0
Action Device in
code charge
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 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
— CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E11 CA689 Ne Speed Sensor Error ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error ENG Electrical system
E15 CA1228 EGR Valve Servo Error 1 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
— D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality PUMP Electrical system
— DA80MA Auto Lub Abnormal PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
— DA2SKQ Model Selection Abnormality PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality PUMP Electrical system
— DGH2KB Hyd Oil Sensor Short PUMP Electrical system
— DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system
— DW43KA Travel Speed Sol. Open Circuit PUMP Electrical system
— DW43KB Travel Speed Sol. Short Circuit PUMP Electrical system
E03 DW45KA Swing Brake Sol. Open Circuit PUMP Electrical system
E03 DW45KB Swing Brake Sol. Short Circuit PUMP Electrical system
— DW91KA Travel Junction Sol. Open Circuit PUMP Electrical system
— DW91KB Travel Junction Sol. Short Circuit PUMP Electrical system
— DWJ0KA Merge-divider Sol. Open Circuit PUMP Electrical system
— DWJ0KB Merge-divider Sol. Short Circuit PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Open Circuit PUMP Electrical system
PC400, 450-7E0 11
Action Device in
code charge
— DWK0KB 2-stage Relief Sol. Short Circuit PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Open Circuit PUMP Electrical system
E02 DXA0KB PC-EPC Sol. Short Circuit PUMP Electrical system
— DXE0KA LS-EPC Sol. Open Circuit PUMP Electrical system
— DXE0KB LS-EPC Sol. Short Circuit PUMP Electrical system
— DXE4KA Service Current EPC Open Circuit PUMP Electrical system
— DXE4KB Service Current EPC Short Circuit PUMP Electrical system
— DY20KA Wiper Working Abnormality MON Electrical system
— DY20MA Wiper Parking Abnormality MON Electrical system
— DY2CKB Washer Drive Short Circuit MON Electrical system
— DY2DKB Wiper Drive (Fwd) Short Circuit MON Electrical system
— DY2EKB Wiper Drive (Rev) Short Circuit MON Electrical system
a This table lists the failed sections in the order of the failure code.
a 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.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
a 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.
12 PC400, 450-7E0
Service menu operation and display 3) Displaying menu screen

The display is changed to the initial display of
Switching to service menu Service Menu program. Select an appropriate
a When using the service menu, switch the item from among the menu.
screen through the following special operation.
1) Confirmation of display
Make sure that the conventional display is
turned on.
a Changing to Service Menu is usually avail-
able only from this conventional display.
Number Service menu

00 Return (Ends the service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Change of maintenance mode
2) Switch operation 05 Setting of telephone No.

Do the following switch operation. 06 Default
q Switch operation: [E] + [1] o [2] o [3] 07 Adjustment
(Enter the numbers while holding E down)
08 Cylinder cut out
09 No injection cranking
4) 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.
PC400, 450-7E0 13
16. Monitoring [01] function a When you have registered all the
The machine monitor monitors signals from the items that can be registered, the
switch sensor actuators on various machine screen will be automatically switched
parts. It allows displaying and checking the to the monitoring information screen.
monitored information through following opera- a Monitored information are transmitted
tions. via communication circuits.Thus the
number of selected items can impact
1) Menu selection the communication speed. If truly real
Select “01 Monitoring” in the initial display time monitoring is required, reduce
of Service Menu and depress [3] switch. the selected items to the minimum.
a For details on the monitoring items,
display unit, etc., refer to the Table for
Monitoring Items.
3) Operation for monitoring

As the monitoring information screen is
displayed, confirm the monitored informa-
tion operating the machine.
2) 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
4) Monitored information holding function

You can hold every monitored information
by pressing [E] while monitoring is contin-
ued.
If you press [R] switch again in this condi-
tion, the currently held information will be
released.
a 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)
a In case of monitoring 1 to 3 items,
move to the monitoring information
screen through any of the following
switch operations after the registra-
tion work has been completed.
q [Hold down [3] switch (for about 3
seconds).
q Select menu “99999” and press [3]
switch.
14 PC400, 450-7E0
5) Machine setup mode switching function

If it becomes necessary to change set-
tings of working mode, select mode, travel
speed and auto-decel while monitoring,
depress the corresponding switch, then
the mode confirmation display is shown.
a Above figure shows the screen dis-

play in P-and E-mode (in B-mode,
part of the symbol mark shape is dif-
ferent from above).
a After confirming the setting, press [3]
switch to return to the monitoring
screen.
a 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
List of Monitoring Items
Code Unit (Default: ISO)

Monitoring item Remarks
No. ISO meter inch
00000 Return (Not display) End menu
Display execution
99999 Display execution (Not display)
menu
00200 Controller Model Select Numbers
00201 Machine ID Numbers
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm 2
psi
01101 R Pump Pressure MPa kg/cm 2
psi
07200 Arm IN PPC Pressure MPa kg/cm 2
psi
07300 Bucket Curl PPC Pressure MPa kg/cm 2
psi
04107 Coolant temperature °C °C °F
14200 Fuel temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
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 V V V
03203 Battery Power Supply V V V
04300 Battery Charge V V V
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 °C °C °F
18500 Charge Temperature °C °C °F
36500 Boost Pressure kPa kg/cm 2
psi
18000 EGR Inlet Pressure-A kPa kg/cm 2
psi
18100 EGR Valve Position mm mm in
36700 Engine Torque Ratio % % %
18700 Engine Output Torque Nm kgm lbft
03000 Fuel Dial Pos Sens Volt V V V
04200 Fuel Level Sensor Vol. V V V
04105 Eng. Water Temp. Vol. Lo V V V
04201 Fuel Temp. Sensor Vol. V V V
04402 Hydr. Temp. Sensor Vol. V V V
37201 Eng Oil Press Sens Volt V V V
37401 Ambient Press Sens Volt V V V
18401 Intake Temp Sens Volt V V V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V
36401 Rail Pressure Sens Volt V V V
16 PC400, 450-7E0

No. ISO meter inch
18101 EGR Valve Pos Sens Volt V V V
17201 PCV Close Timing CA CA CA
17500 Engine Power Mode — — —
31701 Throttle Position % % %
31706 Final Throttle Position % % %
18600 Inject Fueling Command mm3/st mm3/st mm3/st
36200 Rail Press Command MPa kg/cm2 psi
36300 Injection Timing Command CA CA CA
37300 Fuel Rate L/h L/h L/h
01602 2nd Eng. Speed Command % % %
13113 Main Pump Absorb Torque Nm kgm lbft
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
01900 Pressure Switch 1
Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressure Switch 2
Service ON/OFF
Travel Steering ON/OFF
Travel Junction ON/OFF
Swing Brake Sw. ON/OFF
02300 Solenoid Valve 1 Merge-divider ON/OFF
2-Stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid Valve 2 Service Return ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake SW. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2
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
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
PC400, 450-7E0 17

No. ISO meter inch
Aircleaner ON/OFF
Eng. Oil Level ON/OFF
04501 Monitor Input 2
Spare open ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
04502 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
20216 ECM Build Version — — —
20217 ECM CAL Data Ver — — —
18900 ECM Internal Temp °C °C °F
20400 ECM Serial No — — —
20200 Monitor Prog. Version — — —
20212 Pump Con. Prog. Version — — —
18 PC400, 450-7E0
17. Function of abnormality record [02] 3) Contents of display of electrical system

The monitor panel records and classifies the abnormality record information screen
past failure information as into the electrical (1): Occurrence order of abnormalities
and mechanical failures. It allows displaying fro m latest one/Total num ber of
and checking the information through the fol- records
lowing operations. (2): Failure code (Equipment: 4 digits,
1) Menu selection Phenomena: 2 digits)
Select “02 Abnormality Record” in the ini- (3): Elapsed time on service meter from
tial display of Service Menu and depress the first occurrence
[3] switch. (4): Contents of trouble
a See the operator menu “Failure
codes table”.
2) Sub menu selection

Select the sub menu from the abnormality
record menu screen and then press [3] 4) Contents of display of mechanical system
switch. 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 occur-
rence
a See the operator menu “Failure
codes table”.
Number Sub menu of abnormality record

00 Return (End of abnormality record)
01 Electrical systems
02 Mechanical systems
PC400, 450-7E0 19
5) Resetting electrical systems

a Resetting abnormality record (dele-
tion) is possible only with the electri-
cal system. The abnormality record in
the mechanical system cannot be
reset.
a When resetting individual or all infor-
mation 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 follow-
ing 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) 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
2] From the reset screen, do the switch

operation according to the screen
instructions.
a When a specific individual infor-
mation alone is to be reset, be
sure to display the subject infor-
mation 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.
20 PC400, 450-7E0
19. Function of maintenance mode change [04]

Following procedure allows changing the cur- Number Items of the maintenance mode change
rently set operating conditions of the mainte-
Return (End of change in the maintenance
nance display function. 00
mode)
q Set function effective or ineffective
q Change set replacement interval 01 Maintenance mode on/off
02 Engine oil change int.
1) Menu selection 03 Engine oil filter change int.
Select “04 Maintenance Mode Change”
04 Fuel main filter change int.
from the Service Menu and then depress
[3] switch. 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
a 01 and 12 menus are provided for

setting the whole maintenance mode,
while those from 02 through 11 are for
setting individual items.
2) Selection of item to be changed
Select the item to be changed from the 3) Contents of Maintenance Mode On/Off
Maintenance Mode Change Selection q Use (On): The maintenance display
Menu screen. function of all oil and filter-related
items are turned effectual. (Irrespec-
tive of whether “On” or “Off” set for
individual items, this setting prevails)
q Not use (Off): The maintenance dis-
play function of all oils and filter-
related items is disabled (prece-
dence is given to this setting over the
“On” or “Off” selected for an individual
items).
PC400, 450-7E0 21
4) 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 main-
tenance 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 func-
tion for this item is enabled.
(4) Not use (Off): Maintenance display
function for this item is disabled. 2) Changing the display
a The lower limit of this setting is 50 Select “Entry” next to change the display
hours. 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.
5) Description of “Initialize all items”

Select this menu and then press [3]
switch to restore the default value for the
individually set information. 3) Entry and setting phone number
Following the method explained below,
20. Function of phone number entry [05] enter a phone number in the “Phone Num-
When the action code is displayed, following ber Entry” display. (Entry automatically
procedure allows entering or correcting the begins with a cursor at the left end)
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) Menu selection
Select “05 Phone Number Entry” menu
from the Service Menu initial screen and
then depress [3] switch.
22 PC400, 450-7E0
1] Using the numerical keypad, enter 2) Selecting sub menu

the number starting with the cursor Select the target sub menu of setting
position situated at the left end. change and then press [3] switch.
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.
2] Depress [3] switch when all the num-
bers 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 machine-
Number Sub menu of default value
related settings are modifiable. Do necessary
modifications as needed. 00 Return (End of default)
q Working mode as starting switch is turned 01 Mode to be selected as key is turned on
ON 02 Language
q Language used in the service menu
03 Unit
q Unit to be displayed in relation to the mon-
itoring function 04 Presence or absence of attachments
q With/Without attachment
1) Menu selection 3) Mode to be selected as key is turned on

Select “06 Default” menu from the Service Following operation allows specifying the
Menu initial screen and then press [3] working mode to be displayed on the
switch. machine monitor as the starting key is
turned ON.
q P-mode, E-mode, L-mode and B-

mode: If any of above modes is spec-
ified, that mode will be constantly
turned ON as the starting switch is
pressed.
q 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.
PC400, 450-7E0 23
q Default: This setting turns ON the 6) Function for selecting distinction of With/
delivered default mode (P-mode) as Without Service Cir.
the starter switch is pressed. It is possible in this function to set a dis-
a If the engine is stopped from B-mode tinction between with or without attach-
on a machine equipped with the ment.
attachment, this mode will be invari- q With Service Circuit: When an attach-
ably selected as the starter switch is ment is installed.
turned ON the next time independent q Without Service Circuit: When no
of above setting. attachment is installed.
4) Language setting function

Service Menu allows switching the lan-
guage between Japanese and English.
a When the attachment is installed, you

must select “With Service Circuit”
from this screen. Otherwise, the
selection function (the function for
a The default language of the machine sharing the attachment) won't be
monitor is English. available from the operator mode.
a When using the machine monitor,
which is a spare part, in the Japa-
nese-speaking sphere, switch this
function from English to Japanese.
5) 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.
24 PC400, 450-7E0
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.
Torque Torque
Adjustment Adjustment
adjustment adjustment
value value
value value
220 +4.0 kgm 225 –1.0 kgm
221 +3.0 kgm 226 –2.0 kgm
2) Sub menu selection 222 +2.0 kgm 227 –3.0 kgm
Select the sub menu on which setting 223 +1.0 kgm 228 –4.0 kgm
change is to be done and then press [3]
224 0.0 kgm
switch.
4) ATT flow rate adjustment function at com-

pound operation
In the compound operation of attach-
ments, you can adjust the flow rate alloca-
tion of the pump within the range shown in
the table below.
Number Adjustment of sub menu

00 Return (Ends the adjustment)
01 Pump absorption torque
Adjustment of flow to attachment in com-
02
pound operation
3) Function for Pump Absorption Torque Adjustment

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

The operator can perform the engine on cylin-
der 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) Resetting cut out cylinder

Press the switch corresponding to the dis-
abled 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.
2) Selecting cylinder to be disabled

Press a switch corresponding to the cylin-
der 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.
26 PC400, 450-7E0
4) Engine speed holding function [Reference]: Using the holding function effectively
Pressing [E] switch while the engine The engine speed being displayed on the screen
operation on cylinder cut out screen is through the holding function remains on it until the
turned on holds the engine speed and its holding is cancelled. In other words, enabling or
speed is newly displayed in the lower disabling of the cylinder cut out mode does not
space. affect the display.
Pressing [ R ] switch during holding can- Thus, when identifying a failed cylinder quicker, fol-
cels the holding function and deletes the lowing operation is effective.
display in the lower space. (1): Run the engine from the normal operation
a If the holding function is used, the mode (no cylinder cut-out) and then hold the
held speed is displayed in the lower speed of that time.
space along with ( ) and the upper (2): Specify the cylinder to be diagnosed as the cut
space continuously displays the cur- out.
rent speed. (3): Run the engine under the same condition as
a The holding function is usable inde- that for (1). Then compare the engine speed at
pendent of the currently set mode – that time and the held speed being displayed
the cylinder cut out or not. 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 com-
pare 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.
PC400, 450-7E0 27
24. Function of no injection cranking [09]

No injection cranking of the engine is available
from the machine monitor.
No injection cranking denotes stopping injec-
tion of fuel from the injector even if the engine
is run from the starting motor. This mode is
used, for instance, for measurement of com-
pressive pressure.
a This setting must be done after stopping
the engine.
1) 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.
2) The initial screen for the no injection

cranking will appear.
a “Check Communication” will be dis-
played in red.
5) As the preparation for no injection crank-

ing is completed, display of “Under Prepa-
ration” is replaced with “After No
Injection”.
a The letters “After No Injection” are
displayed in green.
6) From this state, crank the engine using
the starting motor.
a Limit the cranking time to 20 seconds
to protect the starting motor.
3) As the checkup is over, following screen

appears.
28 PC400, 450-7E0
7) 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.
8) Press “Return” when ending the no injec-
tion cranking.
a 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
SEN03598-01

© 2008 KOMATSU
All Rights Reserved
30
SEN04149-01

2SHOP
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 1
Procedure for turning on

KOMTRAX terminal 1
When the machine is delivered, KOMTRAX ter-
minal is installed:
a When the machine is delivered, KOMTRAX
terminal is installed (machine with the standard
equipment), implement the following proce-
dure.
1. Reporting of machine model, model num-

ber and serial number
Report the machine model, model number and
serial number to the person responsible to
operation of KOMTRAX. 3) Disconnect the inspecting connector 1
and maintain that state for 5 seconds.
2. Registration of KOMTRAX terminal 4) Turn ON the starting switch and maintain
Th e person responsible to ope ra tion of that state for 5 seconds.
KOMTRAX shall register the subject terminal 5) Disconnect the inspecting connector 2
using the KOMTRAX client PC. and maintain that state for 5 seconds.
a See “KOMTRAX administrator manual” for 6) Connect the inspecting connector 1 again
the procedure. and maintain that state for 5 seconds.
a Above completes the necessary opera- 7) Connect the inspecting connector 2 again
tions. and maintain that state for 5 seconds.
8) Make sure that the KOMTRAX terminal 7-
When installing KOMTRAX terminal after the segment indicator lamp is normally turned
machine is delivered: on.
a When installing KOMTRAX terminal after the
machine is delivered (machine with the retro-
spective equipment), implement the following
procedure.
1. Station opening inspection

a Referencing “Preparation work for trouble-
shooting of electrical system”, confirm the
position of KOMTRAX terminal and the
inspecting connector (the inspecting con-
nector is provided at the bottom of
KOMTRAX terminal).
a Finish the operations of steps 4) to 7)
within 30 seconds.
1) Turn OFF the starting switch and then,
after making sure 5 seconds have
elapsed, proceed to the next step.
2) Make sure visually that the inspecting con-
nectors 1 and 2 are connected.
q Inspecting connector 1:
G02 (female) and G03 (male)
q Inspecting connector 2:
G04 (female) and G05 (male)
2 PC400, 450-7E0
a As [Normal] is indicated, proceed to a If [E: Network error] were displayed,

the next step. check the indication of [LED-C4] ref-
a If [Abnormal] is indicated, repeat the erencing “KOMTRAX terminal lamp
procedure from step 1). indications”. (When CAN is not recog-
nized, check KOMTRAX terminal
CAN harness for troubles. If any,
repair the trouble and repeat the pro-
cedure 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
and maintain that state for 5 seconds.
a Don't return it to OFF position.
11) Set the starting switch to START position
again and make sure the engine 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 sec-
onds to 15 minutes until normal dis-
play is restored).
a If [B: GPS position data sensing error]
were display ed, check the GPS
antenna and cable for external trou-
bles. 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,
cedure 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,
cedure from step 1).
PC400, 450-7E0 3
13) Turn the starting switch OFF. 2. Application for start of use
14) Make sure that the 7-segment indicator a The application for start of use is allowed
lamp comes on normally in 5 seconds. only after the terminal station opening
a As [Normal] is displayed, the station inspection has been successfully ended.
opening inspection is complete. 1) Concerning the machine for which the sta-
a If [Abnormal] is displayed, the inspection opening inspection has been com-
tion is incomplete and must be pleted, report the following information to
repeated from step 1). 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 man-
ual” for the procedure.
a Above completes the necessary oper-
ations.
4 PC400, 450-7E0
Indication by KOMTRAX terminal lamps 1
LEDs for CPU 7-segment lamp and dot for CPU

1. LED-C1 (R signal and ACC signal) 7. 7-segment lamp (Number of mails which are
2. LED-C2 (Condition of starting output) not sent yet)
3. LED-C3 (Condition of S-NET and C signal) 8. Dot (Measuring condition of GPS)
4. LED-C4 (Condition of CAN)
5. LED-C5 (Download writing condition)
6. LED-C6 (Download writing condition)
PC400, 450-7E0 5
The KOMTRAX system indicates the information in the system and contents of processing with the LED dis-
play 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 Indication (*1) Contents of indication
ON Starting switch ACC signal: ON, Alternator R signal: ON
Starting switch ACC Quick blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 signal and alternator
R signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
Condition of engine ON Engine control signal: ON
2 LED-C2
control signal OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
Condition of S-NET Quick blink Starting switch C signal: ON
3 LED-C3 connection and start-
ing switch C signal Slow blink (Unused)
OFF S-NET: Disconnected, Starting switch C signal: OFF
ON CAN: Installed, (Fuel sensor: Not installed)
Condition of CAN Quick blink CAN: Installed, (Fuel sensor: Installed)
4 LED-C4
connection Slow blink CAN: Not installed, (Fuel sensor: Installed)
OFF CAN: Not installed, (Fuel sensor: Not installed)
Download writing mode (Special function of system
5 LED-C5 Condition of Either is ON
administrator)
download writing
6 LED-C6 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
6 PC400, 450-7E0
2. Contents of indication of 7-segment lamp and dot for CPU

a When checking the indication of the LEDs, turn the starting switch to the ON position.
No. Indicator Name/Function Indication (*2) Contents of indication
Figure indicates number of mails which are not sent yet (When
Number of mails Lighting of 0 – 9 10 or more mails are not sent yet, 9 is indicated).
7-seg- Lighting indicates that satellite is captured.
which are not sent yet
7 ment
and satellite captur- Figure indicates number of mails which are not sent yet (When
lamp Quick blink of
ing condition 10 or more mails are not sent yet, 9 is indicated).
0–9
Quick blink indicates that satellite is not captured.
GPS has completed measuring (Position is recognized. See
ON
Measuring condition *3.)
8 Dot
of GPS GPS has not completed measuring (Position is not recognized.
OFF
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 7
Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-
tor 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.
8 PC400, 450-7E0
Preparation work for 2. Engine controller

troubleshooting of electrical 1) Open the engine hood cover on the con-
trol valve side.
system 1 2) Remove cover (1).
a When troubleshooting the monitor panel,
e n g i n e c o n t r o l l e r, p u m p controller and
KOMTRAX terminal-related electrical circuit,
bare applicable connectors according to the
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 (2) is equipped
for an air conditioner, disconnect P15
connector at the cover rear side.
3) Insert or connect troubleshooting T-adapt-

ers in or to connectors ENG, CE02, and
CE03 of engine controller (2).
a Connectors are fixed with screw.
Loosen the screws before discon-
necting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
2) Remove the 3 mounting screws to discon-

nect machine monitor (2) from the mount.
a Use care so that the screws may not
fall into the console.
3) Insert or connect troubleshooting T-
adapter for troubleshooting to connectors
P01, P02 and P70 of machine monitor.
PC400, 450-7E0 9
3. Pump controller 4. KOMTRAX terminal

a The engine throttle and pump controller a KOMTRAX terminal is installed in the
are installed in the cover situated in the cover situated in the rear side of the oper-
rear side of the operator seat. ator seat.
1) Remove the 3 mounting bolts and cover 1) Remove the 3 mounting bolts and cover
(5). (5).
2) Insert or connect troubleshooting T-adapter 2) Insert or connect troubleshooting T-adapter

in or to connectors CP01, CP02 and CP03 in or to connector G01 KOMTRAX of termi-
of pump controller (6). nal (7).
a Connectors are fixed with screw. a The connectors are fixed with screw.
Loosen the screws before discon- Loosen the screws before discon-
necting them. necting them.
a When returned the connectors to their a When returning the connectors to
original positions, fix them by tighten- their original positions, fix them by
ing the screws with the specified tightening the screws with the speci-
torque. fied torque.
3 Screw: 2.82 Nm {0.288 kgm} 3 Screw: 2.82 Nm {0.288 kgm}
a Cable (8) is for the communication
antenna.
a When cable (8) is currently discon-
nected, be sure to connect it again at
this stage to the connector situated
outside of the terminal.
Care must be exercised in this opera-
tion since connecting the cable to the
opposite connector disables the com-
munication.
a Cable (9) is used for the GPS
antenna.
10 PC400, 450-7E0
5. Atmospheric pressure sensor (AMBAIR 6. Boost pressure and temperature sensor

PRESSURE) (BOOST PRESS & IMT)
Engine Ne speed sensor (CRANK SENSOR) a Disconnection and connection of con-
Engine Bkup speed sensor (CAM SENSOR) nector
Engine oil pressure switch (OIL PRESSURE The connector of the boost pressure and
SWITCH) temperature sensor has a special locking
a Disconnection and connection of con- mechanism. Disconnect it according to
nectors steps (a) – (b) and connect it according to
The connectors of the atmospheric pres- steps (c) – (d) as shown below.
sure sensor, engine Ne speed sensor, Disconnection: (a) Unlock – (b) Discon-
engine Bkup speed sensor, engine oil nect connector.
pressure switch have a special locking Connection: (c) Connect connector – (d)
mechanism. Disconnect them according Lock.
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.
a Removal and installation of sensor

A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See "Tools for test-
ing, adjusting, and troubleshooting".
7. Supply pump IMV solenoid (FUEL REGULATOR)

a Removal and installation of sensor a Disconnection and connection of con-
A deep socket is necessary for removal nector
and installation of the engine oil pressure The connector of the supply pump IMV
switch. See "Tools for testing, adjusting, solenoid has a special locking mecha-
and troubleshooting". nism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
PC400, 450-7E0 11
a Precautions for disconnecting connector 8. Common rail pressure sensor (FUEL RAIL
The direction of the lock of the connector PRESS)
varies with the tightened position of the a Disconnection and connection of con-
sensor and the lock may be in a direction nector
in which it is difficult to reset (on the under- The connector of the common rail pres-
side or engine side). sure sensor has a special locking mecha-
In this case, pinch the lock in direction (a) nism. Disconnect it according to steps (a)
with bent-nose nippers [1] (commercially – (b) and connect it according to steps (c)
available), and the lock is reset. – (d) as shown below.
Since the lock clicks when it is reset, dis- Disconnection: (a) Unlock – (b) Discon-
connect the connector after a click is heard. nect connector.
Lock.
a 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)).
12 PC400, 450-7E0
9. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of con-
nector
The connector of the engine coolant tem-
perature 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) Discon-
nect connector.
Lock.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See "Tools for testing,
adjusting, and troubleshooting".
PC400, 450-7E0 13
Procedure for testing diodes 1

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-
type diode are as follows.
2. 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
a The conductive direction of the single diode is apply the black (–) lead to the cath-
indicated on the surface of the diode. ode (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).
1. When using digital circuit tester q The pointer moves in neither of i) and
1) Set the tester in the diode range and ii): The diode is defective (Internal
check the indicated value. disconnection).
a When an ordinary circuit tester is
used, the voltage of the internal bat-
tery 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 indi-
cated.
14 PC400, 450-7E0
Pm clinic service 1
Machine model Model number Service meter
T PC400-7E0
h
T PC450-7E0 T LC
User name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm T 800 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
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 h Times/1st time h/Latest h
AA10NX Times/1st time h/Latest h Times/1st time h/Latest h
AB00KE Times/1st time h/Latest h Times/1st time h/Latest h
B@BAZG Times/1st time h/Latest h Times/1st time h/Latest h
B@BAZK Times/1st time h/Latest h Times/1st time h/Latest h
B@BCNS Times/1st time h/Latest h Times/1st time h/Latest h
B@BCZK Times/1st time h/Latest h Times/1st time h/Latest h
B@HANS Times/1st time h/Latest h Times/1st time h/Latest h
Max. range of engine coolant temperature Max. range of hydraulic oil temperature gauge
gauge
PC400, 450-7E0 15
Items related to engine
16 PC400, 450-7E0
Items related to oil pressure
PC400, 450-7E0 17
Check sheet (PC400/450-7E0)

Model Serial No. Service meter User's name Date of execution Inspector
/ /
1. Engine
Checking condition
Standard Mea-
Service limit
Good
Fuel Work- Auto- Operation of
Bad
No. Check item Left knob Unit value for new sured
control ing decel- work value
switch machine value
dial mode eration equipment
1 Engine speed rpm 1,880 – 1,980 1,880 – 1,980
All levers in
Engine oil MAX MPa 0.29 – 0.69 0.18
2 neutral
pressure {kg/cm2} {3.0 – 7.0} {1.8}
OFF
3 Engine speed rpm 975 – 1,025 975 – 1,025
All levers in
Engine oil MIN OFF MPa Min. 0.08 0.05
4 neutral
pressure P {kg/cm2} {Min. 0.8} {0.5}
5 Engine speed rpm 1,730 – 1,930 1,730 – 1,930
Blow-by ON Arm IN relief kPa Max. 1.76 2.94
6
pressure MAX {mmH2O} {Max. 180} {300}
Engine oil All levers in
7 ON OFF rpm 1,200 – 1,400 1,200 – 1,400
pressure neutral
2. Work equipment speed

Checking condition
Standard Mea-
Service limit
Good
Fuel Work-
Bad
No. Check item Unit value for sured
control ing Checking posture, etc. value
new machine value
dial mode
No load, work equipment PC400-7E0 3.6 – 4.4 Max. 4.8

1 Boom RAISE
extended fully PC450-7E0 3.8 – 4.6 Max. 5.0
PC400-7E0 3.2 – 4.0 Max. 4.3
2 Arm IN P
PC450-7E0 3.2 – 4.0 Max. 4.3
PC400-7E0 3.9 – 4.7 Max. 5.0
3
PC450-7E0 4.2 – 5.2 Max. 5.4
Boom top horizontal
PC400-7E0 3.9 – 4.7 Max. 5.0
4 Arm OUT E
PC450-7E0 4.2 – 5.2 Max. 5.4
PC400-7E0 4.7 – 5.7 Max. 6.0
5 L
MAX PC450-7E0 sec 5.1 – 6.1 Max. 6.3
Boom and arm top horizontal PC400-7E0 3.2 – 4.0 Max. 4.3
6 Bucket CURL
Arm cylinder retracted fully PC450-7E0 3.2 – 4.0 Max. 4.3
7 Swing (5 turns) Work equipment extended fully 29.7 – 36.3 Max. 38
STD 50.6 – 75.8 42.0 – 80.0
LO
P LC 53.8 – 80.8 45.0 – 84.5
STD 38.3 – 51.9 31.5 – 55.0
8 Travel (5 turns) One side of track pushed up MI
LC 40.9 – 55.3 34.0 – 58.0
STD 31.0 – 38.0 28.0 – 41.5
HI
LC 33.1 – 40.3 32.0 – 44.0
18 PC400, 450-7E0
3. Hydraulic drift of work equipment

Checking condition Standard
Mea-
value for Service limit
Good
Fuel Work-
Bad
No. Check item Unit sured
control ing Checking posture, etc. new value
value
dial mode machine
Boom top horizontal PC400-7E0 mm/ Max. 600 Max. 900

Hydraulic drift of
1 Engine stopped Arm cylinder retracted fully
bucket tip PC450-7E0 15 min Max. 700 Max. 1,050
Bucket loaded
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Checked part
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral —
Right track driven idle E1 E2

— — —
Lever moved halfway
5 LS valve
Left track driven idle E1 E2
— — —
Lever moved halfway
MAX P
Swing lock F F
— — —
Swing motor Right swing relief
6
safety valve Swing lock F F
OFF — — —
Left swing relief
Right travel lock G
— — — —
Right forward relief
Main relief valve Right travel lock G
Travel motor — — — —
Right reverse relief
7 Safety valve
Travel junction Left travel lock G
— — — —
valve Left forward relief
Left travel lock G
— — — —
Left reverse relief
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.04 – 3.44 {31 – 35} 2.84 – 3.43 {29 – 35}
B (Work equipment relief pressure,
33.83 – 36.28 {345 – 370} 33.34 – 36.77 {340 – 375}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.29 – 38.74 {370 – 395} 35.79 – 39.23 {365 – 400}
high)
{kg/cm2}
D (Unload pressure) 3.2 – 5.2 {43 – 53} 3.2 – 5.2 {43 – 53}
E (LS differential pressure) 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}
PC400, 450-7E0 19
* Gauge changing work: Change hoses of gauges [3] and [4].

[1] [2] [3a] [4a] [5]
Checking condition
600K 600K 600K 600K 60K
Good
Bad
No. Check item
Fuel Work-
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(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]
Checking condition
600K 600K 60K 60K 60K
Good
Bad
No. Check item
Fuel Work-
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve J4 J4
L — — —
OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
Travel lever oper- — — — —
10 LS-EPC valve P
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated
J1 (PC-EPC valve output pressure 1) Approx. 1.5 {Approx. 15}
Standard value

J4 (PC-EPC valve output pressure 4) MPa Approx. 1.2 {Approx. 12}
J5 (PC-EPC valve output pressure 5) {kg/cm2} Approx. 0.9 {Approx. 9}
K1 (LS-EPC valve output pressure 1) Approx. 2.0 {Approx. 20}
K2 (LS-EPC valve output pressure 2) Approx. 2.6 {Approx. 27}
K3 (LS-EPC valve output pressure 3) 0 {0}
20 PC400, 450-7E0
Visual check of welded structure

a If a crack is found, illustrate its shape in the drawing.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Arm top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T Left T Right Track frame
T Edge plate 6. Arm cylinder bracket 10. Circle bracket
3. Arm top boss T Left T Right T Front T Rear
T Left T Right 7. Boom lower plate T Left T Right
T Left T Right
8. Boom foot
T Left T Right
PC400, 450-7E0 21
Undercarriage troubleshooting report 1

(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model PC400/450-7E0 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry DRY
Soil condition Dealer Shoe width (mm)
Working condition nspector Shoe type TRIPLE
Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 915.6 927.6
R
RH 915.6 927.6
LH 228.90 231.90
M
RH 228.90 231.90
LH 129.0 119.0
RH 129.0 119.0
New Turned
LH 71.5 66.5
New Turned
RH 71.5 66.5
LH 37.0 22.0
RH 37.0 22.0
LH 148.0 134.0
Front
RH 148.0 134.0
LH 148.0 134.0
Rear
RH 148.0 134.0
LH 22.0 28.0
Front
RH 22.0 28.0
LH 22.0 28.0
Rear
RH 22.0 28.0
1 LH 200.0 188.0
2 LH 200.0 188.0
3 LH 200.0 188.0
4 LH 200.0 188.0
5 LH 200.0 188.0
6 LH 200.0 188.0
7 LH 200.0 188.0
8 LH 200.0 188.0
9 LH 200.0 188.0
10 LH 200.0 188.0
1 RH 200.0 188.0
2 RH 200.0 188.0
3 RH 200.0 188.0
4 RH 200.0 188.0
5 RH 200.0 188.0
6 RH 200.0 188.0
7 RH 200.0 188.0
8 RH 200.0 188.0
9 RH 200.0 188.0
1.3 10 RH 200.0 188.0
LH 0.0 6.0
RH 0.0 6.0
Remarks:
22 PC400, 450-7E0
PC400, 450-7E0 23
SEN04149-01

© 2008 KOMATSU
All Rights Reserved
24
SEN04150-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Before carrying out troubleshooting when failure code is displayed ............................................................... 6
PC400, 450-7E0 1
SEN04150-02 40 Troubleshooting
Failure codes table 1

Action Device in Reference
code charge document No.
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low ENG Mechanical system
— B@BAZK Eng. Oil Level Low MON Mechanical system
— B@BCNS Eng. Water Overheat ENG Mechanical system
— B@BCZK Eng. Water Lvl Low MON Mechanical system
— 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
Troubleshooting
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system by failure code
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system (Display of code),
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system Part 1
SEN03601-02
E15 CA221 Ambient Press Sens High Error ENG Electrical system
E15 CA222 Ambient Press Sens Low 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
E11 CA271 IMV/PCV1 Short Error 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
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system Troubleshooting
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system by failure code
(Display of code),
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system Part 2
E10 CA441 Battery Voltage Low Error ENG Electrical system SEN03602-01
E10 CA442 Battery Voltage High Error ENG Electrical system
2 PC400, 450-7E0
40 Troubleshooting SEN04150-02

E11 CA449 Rail Press Very High Error ENG Electrical system
E11 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
— CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E11 CA689 Ne Speed Sensor Error ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system Troubleshooting
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system by failure code
(Display of code),
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system Part 2
E11 CA2249 Rail Press Very Low Error ENG Electrical system SEN03602-01
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
— D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP 5V Sensor 1 Power Abnormality PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
— DA2SKQ Model Selection Abnormality PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality PUMP Electrical system
— DGH2KB Hyd Oil Sensor Short PUMP Electrical system
— DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP Electrical system
Bucket Curl PPC Press Sensor Abnor-
— DHS4MA PUMP Electrical system
mality
Troubleshooting
— DW43KA Travel Speed Sol. Open Circuit PUMP Electrical system
by failure code
— DW43KB Travel Speed Sol. Short Circuit PUMP Electrical system (Display of code),
E03 DW45KA Swing Brake Sol. Open Circuit PUMP Electrical system Part 3
SEN03603-01
E03 DW45KB Swing Brake Sol. Short Circuit PUMP Electrical system
— DW91KA Travel Junction Sol. Open Circuit PUMP Electrical system
— DW91KB Travel Junction Sol. Short Circuit PUMP Electrical system
— DWJ0KA Merge-divider Sol. Open Circuit PUMP Electrical system
— DWJ0KB Merge-divider Sol. Short Circuit PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Open Circuit PUMP Electrical system
— DWK0KB 2-stage Relief Sol. Short Circuit PUMP Electrical system
PC400, 450-7E0 3

E02 DXA0KA PC-EPC Sol. Open Circuit PUMP Electrical system
E02 DXA0KB PC-EPC Sol. Short Circuit PUMP Electrical system
— DXE0KA LS-EPC Sol. Open Circuit PUMP Electrical system
— DXE0KB LS-EPC Sol. Short Circuit PUMP Electrical system
Troubleshooting
— DXE4KA Service Current EPC Open Circuit PUMP Electrical system by failure code
— DXE4KB Service Current EPC Short Circuit PUMP Electrical system (Display of code),
— DY20KA Wiper Working Abnormality MON Electrical system Part 3
SEN03603-01
— DY20MA Wiper Parking Abnormality MON Electrical system
— DY2CKB Washer Drive Short Circuit MON Electrical system
— DY2DKB Wiper Drive (Fwd) Short Circuit MON Electrical system
— DY2EKB Wiper Drive (Rev) Short Circuit MON Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
4 PC400, 450-7E0
PC400, 450-7E0 5
Before carrying out troubleshooting when failure code is displayed 1

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 fus-
ible links to see if the power is supplied normally.
Type of Fuse
Fusible link Fuse No. Destination of power
power supply capacity
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
Switch power F04 3 20A Machine monitor
supply (65A) Wiper motor
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Rotary lamp (If equipped)
Switch power F04 8 10A Relay for lamp
supply (65A) Radio, speaker
9 10A
Left-hand knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
Switch power F04
13 20A Lamp, lamp relay drive
supply (65A)
14 10A Optional power supply (1)
Travel alarm, 12V power supply
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant F05 Starting switch
17 10A
power supply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
6 PC400, 450-7E0
Locations of fusible links and fuse No.
PC400, 450-7E0 7
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 simulta-
neously (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.
8 PC400, 450-7E0
a Power supply connector (CP03) of pump controller
PC400, 450-7E0 9
SEN04150-02

© 2009 KOMATSU
All Rights Reserved
10
SEN03600-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
Information related to 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 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k 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.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k 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 pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a shortcut 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 symp-
toms.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

hurry to disassemble the components. 1) Is there any sign of irregularities of the
If components are disassembled immediately machine?
after any failure occurs: 2) Make checks before starting day's work.
q Parts that have no connection with the fail- 3) Make checks of other items.
ure or other unnecessary parts will be dis- 4) Other maintenance items can be checked
assembled. externally, so check any item that is con-
q It will become impossible to find the cause sidered to be necessary.
of the failure. 4. Confirming failure
It will also cause a waste of manhours, parts, Confirm the extent of the failure yourself, and
or oil or grease, and at the same time, will also judge whether to handle it as a real failure or
lose the confidence of the user or operator. For as a problem with the method of operation, etc.
this reason, when carrying out troubleshooting, a When operating the machine to reenact
it is necessary to carry out thorough prior the troubleshooting symptoms, do not
investigation and to carry out troubleshooting carry out any investigation or measure-
in accordance with the fixed procedure. ment that may make the problem worse.
2. Points to ask user or operator 5. Troubleshooting

1) Have any other problems occurred apart Use the results of the investigation and inspec-
from the problem that has been reported? tion in Items 2 – 4 to narrow down the causes
2) Was there anything strange about the of failure, then use the troubleshooting table or
machine before the failure occurred? troubleshooting flowchart to locate the position
3) Did the failure occur suddenly, or were of the failure exactly.
there problems with the machine condition a The basic procedure for troubleshooting is
before this? as follows.
4) Under what conditions did the failure 1] Start from the simple points.
occur? 2] Start from the most likely points.
5) Had any repairs been carried out before 3] Investigate other related parts or
the failureWhen were these repairs carried information.
out?
6) Has the same kind of failure occurred 6. Measures to remove root cause of failure
before? 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 investi-
gate why the problem occurred. Then, remove
the root cause.
2 PC400, 450-7E0
Sequence of events in troubleshooting (Rev. 2007.12)
PC400, 450-7E0 3
Checks before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of hydraulic oil level — Add oil
4. Check of hydraulic oil strainer — Clean and drain
Lubricating
5. Check of swing machinery oil level — Add oil
oil, Coolant
6. Check of level and type of engine oil (in oil pan) — 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
— Retighten or replace
corrosion
Electrical 2. Check of alternator terminals and wiring for looseness and
equipment corrosion
3. Check of starting motor terminals and wiring for looseness
and corrosion
Hydraulic, 1. Check for abnormal noise and smell — Repair

Mechanical 2. Check of oil leakage — Repair
equipment 3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 30 V Replace
2. Check of electrolyte level — Add or replace
3. Check of wires for discoloration, burn, and removal of
— Replace
cover
4. Check for released wire clamp and drooping wire — Repair
Electric, 5. Check of wires for wetness (Check connectors and termi- Disconnect the con-
electrical —
nals for wetness, in particular) nectors and dry
equipment
6. Check of fuse for disconnection and corrosion — Replace
After operating for
7. Check of alternator voltage (while engine speed is at mid-
several minutes: Replace
dle or higher)
27.5 – 29.5 V
8. Check of battery relay for operating sound (when starting
— Replace
switch is turned ON or OFF)
4 PC400, 450-7E0
Classification and troubleshooting steps 1

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 abnor-
mality 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 trouble-
shooting corresponding to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
PC400, 450-7E0 5
Information in troubleshooting table 1

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 Trouble name displayed in abnormality record machine moni-
Display on machine Trouble
machine monitor
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine con-
machine moni-
troller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<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 bro-
ken.
• 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
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• 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”, dis-
connect 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.
6 PC400, 450-7E0
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
q Connector No.: Indicates (Model – Number of pins) and
(Color).
q “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.
q Arrow (⇔): Roughly shows the location on the machine.
PC400, 450-7E0 7
Possible Problems and Troubleshooting No.
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
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 dis- According to
2
played in electrical system abnormality record displayed
When abnormality record is checked, failure code is dis- code
3
played in mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 (1)
Engine rotates, but exhaust gas does not
6 Engine does S-2 (2)
come out
not start
Engine emits exhaust gas, but it does not
7 S-2 (3)
start
Engine does not pick up smoothly (follow-up performance
8 S-3
is poor)
9 Engine stops during operations 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
Oil is in coolant, coolant spurts back or coolant level goes
16 S-11
down
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 H-5
21 Automatic warm-up system does not operate E-3
22 Preheater does not operate E-4
Phenomena related to work equipment, swing and travel
Speed or power of whole work equipment, travel, and
23 H-1 S-6
swing is low
24 Engine speed lowers extremely or engine stalls H-2 S-4
Work equipment, swing, and travel mechanism do not
25 E-5 H-3
move
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
8 PC400, 450-7E0
Troubleshooting
code
33 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other
34 H-13
parts of work equipment move
35 Power maximizing function does not work E-6, 18 – 23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part
36 H-16
loaded more is low
When machine swings and raises boom simultaneously,
37 H-17
boom rising speed is low
When work equipment and travels simultaneously, travel
38 H-18
speed lowers largely
Phenomena related to travel
39 Machine deviates during travel H-19
40 Travel speed is low E-25 H-20
41 Machine is not steered well or steering power is low E-25, 26 H-21
42 Travel speed does not change or travel speed is low or high 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 H-24
45 Swing acceleration or swing speed is low H-25
Upper structure overruns remarkably when it stops swing-
46 H-26
ing
47 Large shock is made when upper structure stops swinging H-27
Large sound is made when upper structure stops swing-
48 H-28
ing
49 Hydraulic drift of swing H-29
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
Contents of display by machine monitor are different from
52 E-9
applicable machine
Radiator coolant level monitor lights up in red during
53 B@BCZK
check before starting
Engine oil level monitor lights up in red during check
54 B@BAZK
before starting
Maintenance interval monitor lights up in red during check
55 See the Operation and Maintenance Manual.
before starting
Charge level monitor lights up in red while engine is run-
56 AB00KE
ning
57 Fuel level monitor lights up in red while engine is running E-10
Air cleaner clogging monitor lights up in red while engine
58 AA10NX
is running
Engine coolant temperature monitor lights up in red while
59 B@BCNS
engine is running
Hydraulic oil temperature monitor lights up in red while
60 B@HANS
engine is running
PC400, 450-7E0 9
Troubleshooting
code
Engine coolant temperature gauge does not indicate nor-
61 E-11
mally
Hydraulic oil temperature gauge does not indicate nor-
62 E-12
mally
63 Fuel level gauge does not indicate normally E-13
64 Swing lock monitor does not indicate normally E-14
Machine monitor display anything even when operated on
65 E-15
monitor switch section
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” nor-
68 E-18
mally
Monitoring function does not display “Boom LOWER” nor-
69 E-19
mally
70 Monitoring function does not display “Arm IN” normally E-20
71 Monitoring function does not display “Arm OUT” normally E-21
Monitoring function does not display “Bucket CURL” nor-
72 E-22
mally
Monitoring function does not display “Bucket DUMP” nor-
73 E-23
mally
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” nor-
76 E-26
mally
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
Connection table for connector pin numbers (Rev. 2009.04)
a 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
12 PC400, 450-7E0
PC400, 450-7E0 13
14 PC400, 450-7E0
PC400, 450-7E0 15
16 PC400, 450-7E0
PC400, 450-7E0 17
18 PC400, 450-7E0
PC400, 450-7E0 19
20 PC400, 450-7E0
PC400, 450-7E0 21
22 PC400, 450-7E0
PC400, 450-7E0 23
24 PC400, 450-7E0
PC400, 450-7E0 25
26 PC400, 450-7E0
PC400, 450-7E0 27
28 PC400, 450-7E0
PC400, 450-7E0 29
30 PC400, 450-7E0
PC400, 450-7E0 31
32 PC400, 450-7E0
PC400, 450-7E0 33
34 PC400, 450-7E0
PC400, 450-7E0 35
36 PC400, 450-7E0
PC400, 450-7E0 37
38 PC400, 450-7E0
PC400, 450-7E0 39
40 PC400, 450-7E0
PC400, 450-7E0 41
42 PC400, 450-7E0
PC400, 450-7E0 43
44 PC400, 450-7E0
PC400, 450-7E0 45
46 PC400, 450-7E0
T- branch box and T- branch adapter table 1

(Rev. 2009.03)
a 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.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
PC400, 450-7E0 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q 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 q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
48 PC400, 450-7E0
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
PC400, 450-7E0 49
SEN03600-02

© 2009 KOMATSU
All Rights Reserved
50
SEN03601-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
Troubleshooting by failure code
(Display of code), Part 1
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
PC400, 450-7E0 1
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................................................................................ 34
Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 36
Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 38
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 40
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 42
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 43
Failure code [CA234] Eng Overspeed .......................................................................................................... 45
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 46
Failure code [CA263] Fuel Temp Sensor High Error..................................................................................... 48
Failure code [CA265] Fuel Temp Sensor Low Error...................................................................................... 50
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 51
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 52
Failure code [CA273] PCV2 Short Error ....................................................................................................... 54
Failure code [CA274] PCV2 Open Error ....................................................................................................... 55
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error ................................................................................. 56
2 PC400, 450-7E0
PC400, 450-7E0 3
Failure code [AA10NX] Aircleaner Clogging 1

Action code Failure code Aircleaner Clogging
Trouble
— AA10NX (Mechanical system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch was opened (disconnected
trouble with GND).
Action of
machine • None in particular.
monitor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• If an air cleaner clogging caution symbol appears on the machine monitor while the engine is run-
Related ning, this failure code will be recorded.
information • Input from the air cleaner clogging switch (ON/OFF) can be checked with monitoring function.
(Code 04501: Monitor Input 2)

Clogging of air cleaner a Check the air cleaner for clogging and then clean or
1
(when system is normal) replace it if clogged.
a Prepare with starting switch OFF, then start engine and
carry out troubleshooting.
Defective air cleaner clog-
2 ging switch (internal discon- P23 (male) Air cleaner Resistance
nection) Value in normal state Max. 1 z
Between (1) – (2)
Value when clogged Min. 1 Mz
Possible causes
and standard
value in normal carry out troubleshooting.
Disconnection in wiring harness
state Wiring harness between P02 (female) (5) – Resis-
3 (Disconnection in wiring or Max. 1 z
P23 (female) (1) tance
defective contact in connector)
Wiring harness between P23 (female) (2) – Resis-
Max. 1 z
chassis ground tance
4 Defective machine monitor P02 Air cleaner Voltage
Between (5) – Value in normal state Max. 1 V
chassis ground Value when clogged 20 – 30 V
4 PC400, 450-7E0
Circuit diagram related to air cleaner clogging switch of machine monitor
PC400, 450-7E0 5
Failure code [AB00KE] Charge Voltage Low 1

Action code Failure code Charge Voltage Low
Trouble
— AB00KE (Mechanical system)
Contents of
• While engine is running, power generation signal from the alternator is not input.
trouble
Action of
monitor
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
• If a charge level caution symbol appears on the machine monitor while the engine is running, this
Related failure code will be recorded.
information • Input from alternator (voltage) can be checked with monitoring function.
(Code 04300: Charge voltage)

Defective alternator
1 Alternator Engine speed Voltage
(Low power generation)
Between R terminal –
Medium or higher 27.5 – 29.5 V
chassis ground
a Prepare with starting switch OFF, then carry out trouble-
Disconnection in wiring harness shooting without turning starting switch ON.
2 (Disconnection in wiring or
Possible causes defective contact in connector) Wiring harness between P02 (female) (11) – Resis-
Max. 1 z
and standard J02 – Alternator R terminal tance
value in normal
a Prepare with starting switch OFF, then turn starting
state
switch ON and carry out troubleshooting.
Ground fault in wiring harness
3
(Short circuit with GND circuit) Wiring harness between P02 (female) (11) – Resis-
J02 – Alternator R terminal, – D01 (female) Min. 1 Mz
tance
(6) – M17 (female) (2)
4 Defective machine monitor P02 Engine speed Voltage
Between (11) –
chassis ground
6 PC400, 450-7E0
Circuit diagram related to starting and charge of machine monitor
PC400, 450-7E0 7
Failure code [B@BAZG] Eng Oil Press. Low 1

Action code Failure code Eng Oil Press. Low
Trouble
— B@BAZG (Mechanical system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (sensor contact opened).
Action of • Displays engine oil pressure monitor on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
machine
• Engine oil pressure sensor signal is input to engine controller and then transmitted to machine moni-
Related
tor.
information
• Method of reproducing failure code: Start engine.

Lowering of engine oil pres- a Determine the cause and check the damage to the
1 sure engine and then modify it.
(when system is normal)
Defective engine oil pressure
2 sensor POIL (male) Engine Resistance
(Internal defect) When started Min. 1 Mz
Between (3) –
chassis ground When stopped Max. 1 z
Possible causes Disconnection in wiring harness shooting without turning starting switch ON.
and standard 3 (Disconnection in wiring or
value in normal defective contact in connector) Wiring harness between CE01 (female) (37) – Resis-
Max. 1 z
state POIL (female) (1) tance
shooting without turning starting switch ON.
4
(Short circuit with GND circuit) Wiring harness between CE01 (female) (37) – Resis-
POIL (female) (1) and chassis ground (when Min. 1 Mz
tance
engine is started)
5 Defective engine controller CE01 Engine Resistance
Between (37) – When started Min. 1 Mz
chassis ground When stopped Max. 1 z
8 PC400, 450-7E0
Circuit diagram related to engine oil pressure
PC400, 450-7E0 9
Failure code [B@BAZK] Eng. Oil Level Low 1

Action code Failure code Eng. Oil Level Low
Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of
• Displays engine oil level monitor on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
machine
• Engine oil level switch signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch ON.

a Check the engine oil level and add new oil.
Lowering of engine oil level
1 (If this phenomenon frequently occurs, investigate the
(when system is normal)
cause.)
Defective engine oil level P44 (male) Engine oil level Resistance
2 switch
(Internal disconnection) Value in normal state Max. 1 z
Between (1) – chas-
Possible causes sis ground Value when coolant
Min. 1 Mz
and standard level is low
value in normal a Prepare with starting switch OFF, then carry out trouble-
state Disconnection in wiring harness shooting without turning starting switch ON.
defective contact in connector) Wiring harness between P02 (female) (8) – Resis-
Max. 1 z
P02 Engine oil level Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
Between (8) –
chassis ground Value when coolant
20 – 30 V
level is low
Circuit diagram related to engine oil level switch of machine monitor
10 PC400, 450-7E0
PC400, 450-7E0 11
Failure code [B@BCNS] Eng. Water Overheat 1

Action code Failure code Eng. Water Overheat
Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating
trouble of engine coolant (above 102°C).
Action of
• Displays engine coolant temperature monitor with red on machine monitor.
machine
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
monitor
Problem that
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Related
• Engine coolant temperature can be checked with monitoring function (Code 04107: Engine coolant
information
temperature)

Overheating of engine a Determine the cause and check the damage to the
1
(when system is normal) engine and then modify it.
Defective engine coolant Engine coolant tem-
TWTR (male) Resistance
2 temperature sensor perature
(Internal short circuit) Between (A) – (B) 90 – 3.5 kz
Possible causes Between (A) – 10 – 100°C
Min. 1 Mz
and standard chassis ground
value in normal
state Ground fault in wiring har- shooting without turning starting switch ON.
3 ness
(Short circuit with GND circuit) Between wiring harness of CE01 (female) Resis-
Min. 1 Mz
(15) – TWTR (female) (A) and chassis ground tance
Engine coolant
4 Defective engine controller CE01 (female) Resistance
temperature
Between (15) –
10 – 100°C 90 – 3.5 kz
chassis ground
12 PC400, 450-7E0
Circuit diagram related to engine coolant temperature sensor of machine monitor
PC400, 450-7E0 13
Failure code [B@BCZK] Eng. Water Lvl Low 1

Action code Failure code Eng. Water Lvl Low
Trouble
— B@BCZK (Mechanical system)
Contents of • While engine was running, signal circuit of radiator coolant level switch was opened (disconnected
trouble with GND).
Action of
monitor
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• If radiator coolant level caution symbol appears on the machine monitor while the engine is running,
Related this failure code will be recorded.
information • Input from the radiator coolant level switch (ON/OFF) can be checked with monitoring function.

Lowering of radiator coolant level a Check the coolant level and add coolant.
1
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
Defective radiator coolant P24 (male) Radiator coolant level Resistance
2 level switch
(internal disconnection) Value in normal state Max. 1 z
Between (1) – (2) Value when coolant
Min. 1 Mz
level is low
Possible causes
and standard
value in normal shooting without turning starting switch ON.
defective contact in connector) P24 (female) (1) tance
Max. 1 z
P02 Radiator coolant level Voltage
Value in normal state Max. 1 V
Between (3) –
chassis ground Value when coolant
20 – 30 V
level is low
14 PC400, 450-7E0
Circuit diagram related to radiator coolant level switch of machine monitor
PC400, 450-7E0 15
Failure code [B@HANS] Hydr. Oil Overheat 1

Action code Failure code Hydr. Oil Overheat
Trouble
— B@HANS (Mechanical system)
Contents of
• While engine was running, signal of hydraulic oil temperature sensor is over 102°C.
trouble
Action of
monitor
Problem that
appears on • If machine is operated as it is, hydraulic components may be seized.
machine
• If hydraulic oil temperature gauge enters red range on the machine monitor while the engine is run-
ning, this failure code will be recorded.
Related
• Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
information
tion.
(Code 04402: Hydraulic oil temperature sensor voltage)

Hydr. Oil Overheat a Determine the cause and check the damage to the
1
(when system is normal) hydraulic components and then modify it.
Defective hydraulic oil tem- Hydraulic oil
P22 (male) Resistance
2 perature sensor temperature
(Internal short circuit) Between (1) – (2) 90 – 3.5 kz
Between (2) – 10 – 100°C
Possible causes Min. 1 Mz
chassis ground
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out trouble-
state ness shooting without turning starting switch ON.
3
(Short circuit with GND cir- Wiring harness between P02 (female) (12) – Resis-
cuit) Min. 1 Mz
P22 (female) (2) and chassis ground tance
Hydraulic oil
P02 (female) Resistance
4 Defective machine monitor temperature
Between (12) – (13) 90 – 3.5 kz
Between (12) – 10 – 100°C
Min. 1 Mz
chassis ground
16 PC400, 450-7E0
Circuit diagram related to hydraulic oil temperature sensor of machine monitor
PC400, 450-7E0 17
Failure code [CA111] ECM Critical Internal Failure 1

Action code Failure code ECM Critical Internal Failure
Trouble
E10 CA111 (Engine controller system)
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
information

Fuse No.19 or fusible link F05 may be defective. Check it directly.
1 Defective fuse or fusible link (If fuse is broken or fusible link is shut down, circuit probably has
ground fault.)
Disconnection in wiring har- shooting without turning starting switch ON.
ness Wiring harness between CE03 (female) (3) – Resis-
2 Max. 1 z
(Disconnection in wiring or battery (+) tance
Wiring harness between CE03 (female) (1) – Resis-
Possible causes Max. 1 z
and standard
state shooting without turning starting switch ON.
Ground fault in wiring harness Wiring harness between CE03 (female) (3) – Resis-
3 Min. 1 Mz
(Short circuit with GND circuit) battery (+) and chassis ground tance
Min. 1 Mz
4 Defective engine controller
CE03 Voltage
Between (3) – (1) 20 – 30 V
18 PC400, 450-7E0
Circuit diagram related to controller power supply
PC400, 450-7E0 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1

Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of
• Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
controller
Problem that
• Engine cannot be started. (Engine is stopped.)
appears on
• Engine stops (during operations).
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Possible causes Defective installation of Ne Ne speed sensor may be installed defectively. Check it directly.
3
and standard speed sensor (Defective installation of sensor itself, internal defect of flywheel, etc.)
value in normal Bkup speed sensor may be installed defectively. Check it directly.
state Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply
speed sensor
pump, etc.)
Defective connection of sensor Ne speed sensor and Bkup speed sensor may be connected
5
connector (Wrong connection) defectively (or connected to wrong parts). Check them directly.
If causes 1 – 5 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
20 PC400, 450-7E0
Failure code [CA122] Chg Air Press Sensor High Error 1

Action code Failure code Chg Air Press Sensor High Error
Trouble
Contents of
• High pressure error occurred in charge air pressure sensor circuit.
trouble
Action of
• Fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
controller
Problem that
appears on • Engine does not accelerate easily.
machine
Related
information

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
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 PIM Voltage
2 sensor Between (1) – (3) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Wiring harness between CE01 (female) (37) Resis-
Disconnection in wiring harness Max. 1 z
– PIM (female) (1) tance
defective contact in connector) Wiring harness between CE01 (female) (44) Resis-
Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal Between wiring harness of CE01 (female) Resis-
Min. 1 Mz
state Ground fault in wiring harness (37) – PIM (female) (1) and chassis ground tance
4
Min. 1 Mz
(44) – PIM (female) (2) and chassis ground tance
Between wiring harness of CE01 (female) Resis-
Min. 1 Mz
(47) – PIM (female) (3) and chassis ground tance
Wiring harness between CE01 (female) (37)
Resis-
– PIM (female) (1) and between CE01 Min. 1 Mz
tance
(female) (44) – PIM (female) (2)
Short circuit in wiring harness
5
(with another wiring harness) Wiring harness between CE01 (female) (37) Resis-
tance
Resis-
tance
switch ON or start engine and carry out troubleshooting.
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
PC400, 450-7E0 21
Circuit diagram related to charge pressure sensor
22 PC400, 450-7E0
Failure code [CA123] Chg Air Press Sensor Low Error 1

Action code Failure code Chg Air Press Sensor Low Error
Trouble
Contents of
• Low pressure error occurred in charge air pressure sensor circuit.
trouble
Action of
• Fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
controller
Problem that
appears on • Engine does not accelerate easily.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
PC400, 450-7E0 23
Failure code [CA131] Throttle Sensor High Error 1
Action code Failure code Throttle sensor high error

Trouble
Contents of
• Signal circuit of fuel control dial detected high voltage.
trouble
• If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just
Action of con- before detection of trouble and continues operation.
troller • If starting switch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel con-
Related infor-
trol dial voltage)
mation

Defective throttle sensor If failure code [CA2185] is also indicated, carry out troubleshooting
1
power supply system for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
P20 Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
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.
Hot short in wiring harness and carry out troubleshooting.
3 (Short circuit with 5V/24V cir-
Possible causes Wiring harness between CE02 (female) (9) –
cuit) Voltage Max. 1 V
and standard P20 (female) (2) and chassis ground
value in normal
a Prepare with starting switch OFF, then carry out troubleshoot-
state
Short circuit in wiring har- ing without turning starting switch ON.
4 ness Wiring harness between CE02 (female) (9) –
(with another wiring harness) P20 (female) (2) and between CE02 (female) Resis- Min.
tance 100 kz
(22) – P20 (female) (1)
Connecting parts between fuel control dial – machine wiring har-
ness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
CE02 Voltage
24 PC400, 450-7E0
Circuit diagram related to fuel control dial throttle sensor
PC400, 450-7E0 25
Failure code [CA132] Throttle Sensor Low Error 1

Action code Failure code Throttle Sensor Low Error
Trouble
Contents of
• Low error occurred in throttle sensor circuit.
trouble
Action of
• Use a signal other than throttle sensor to set the throttle position for control.
controller
Problem that
appears on
machine
Related
information

and standard
state
26 PC400, 450-7E0
Failure code [CA135] Eng Oil Press Sensor High Error 1

Action code Failure code Eng Oil Press Sensor High Error
Trouble
Contents of
• High pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related
information

1
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
POIL Voltage
Defective oil pressure sensor
2 Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal defect)
POIL (female) (1) tance
defective contact in connector) Wiring harness between CE01 (female) (47) – Resis-
Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal Between wiring harness of CE01 (female) Resis-
Min. 1 Mz
state Ground fault in wiring harness (37) – POIL (female) (1) and chassis ground tance
4
Min. 1 Mz
(47) – POIL (female) (2) and chassis ground tance
Between wiring harness of CE01 (female) Resis-
Min. 1 Mz
(13) – POIL (female) (3) and chassis ground tance
Wiring harness between CE01 (female) (37) –
Resis-
POIL (female) (1) and between CE01 Min. 1 Mz
tance
(female) (47) – POIL (female) (2)
5
(with another wiring harness) Wiring harness between CE01 (female) (37) – Resis-
tance
Resis-
tance
CE01 Voltage
PC400, 450-7E0 27
Circuit diagram related to oil pressure sensor
28 PC400, 450-7E0
Failure code [CA141] Eng Oil Press Sensor Low Error 1

Action code Failure code Eng Oil Press Sensor Low Error
Trouble
Contents of
• Low pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
PC400, 450-7E0 29
Failure code [CA144] Coolant Temp Sens High Error 1

Action code Failure code Coolant Temp Sens High Error
Trouble
Contents of
• High temperature error occurred in coolant temperature sensor circuit.
trouble
Action of
• Fixes coolant temperature value (90°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

TWTR (male) Coolant temperature Resistance
Defective coolant tempera- 0°C 30 – 37 kz
1 ture sensor
25°C 9.3 – 10.7 kz
(Internal defect)
Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Possible causes 2 (Disconnection in wiring or Max. 1 z
TWTR (female) (A) tance
and standard defective contact in connector)
value in normal Wiring harness between CE01 (female) (38) – Resis-
Max. 1 z
state TWTR (female) (B) tance
Ground fault in wiring harness ing without turning starting switch ON.
3
(Short circuit with GND circuit) Between wiring harness of CE01 (female) (15) Resis-
Min. 1 Mz
– TWTR (female) (A) and chassis ground tance
CE01 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) – (38) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
30 PC400, 450-7E0
Circuit diagram related to coolant temperature sensor
PC400, 450-7E0 31
Failure code [CA145] Coolant Temp Sens Low Error 1

Action code Failure code Coolant temperature sensor low error
Trouble
Contents of
• Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of con-
• Fixes coolant temperature value and continues operation.
troller
Problem that
• Exhaust gas becomes white.
appears on
• Overheat prevention function does not work.
machine
Related infor-
mation

ing without turning starting switch ON.
C5 (male) Temperature Resistance
0°C 30 – 37 kz
Defective coolant tempera- 25°C 9.3 – 10.7 kz
1
ture sensor Between (A) – (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (B) – chas-
All range Min. 100 kz
sis ground
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
2
(Short circuit with GND cir- Wiring harness between CE01 (female) (15) Resis- Min.
cuit) – TWTR (female) (A) and chassis ground tance 100 kz
Possible causes Short circuit in wiring har- ing without turning starting switch ON.
and standard
3 ness Between CE01 (female) (15) – each of CE01
value in normal Resis- Min.
(with another wiring harness) (female) pins (With all wiring harness con-
state tance 100 kz
nectors disconnected)
Connecting parts between coolant temperature sensor – engine wir-
ing harness – engine controller may be defective. Check them
Defective wiring harness directly.
4
connector • Looseness of connector, breakage of lock, or breakage of seal
CE01 (female) Temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) – (38) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
sis ground
32 PC400, 450-7E0
Circuit diagram related to engine coolant temperature sensor
PC400, 450-7E0 33
Failure code [CA153] Chg Air Temp Sensor High Error 1

Action code Failure code Charge air temperature sensor high error
Trouble
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected high voltage.
trouble
Action of con-
• Fixes charge temperature value and continues operation.
troller
Problem that
appears on
• Engine protection function based on boost temperature does not work
machine
Related infor-
mation

TIM (male) Temperature Resistance
Defective boost pressure,
1 temperature sensor [temper- 0°C 5.5 – 6.1 kz
ature signal system] 25°C 1.9 – 2.1 kz
Between (A) – (B)
40°C 1.1 – 1.2 kz
100°C 180 – 185 z
Disconnection in wiring har- ing without turning starting switch ON.
ness
– TIM (female) (A) tance
defective contact in connec-
tor) Wiring harness between CE01 (female) (47) Resis-
Max. 10 z
– TIM (female) (B) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard
Short circuit in wiring har- ing without turning starting switch ON.
value in normal
state 3 ness Between CE01 (female) (23) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resis- Min.
tance 100 kz
Connecting parts between boost pressure, temperature sensor –
engine wiring harness – engine controller may be defective. Check
Defective wiring harness them directly.
4
5 Defective engine controller 0°C 5.5 – 6.1 kz
25°C 1.9 – 2.1 kz
Between (23) – (47)
40°C 1.1 – 1.2 kz
100°C 180 – 185 z
34 PC400, 450-7E0
Circuit diagram related to charge temperature sensor
PC400, 450-7E0 35
Failure code [CA154] Chg Air Temp Sensor Low Error 1
Action code Failure code Charge air temperature sensor low error
Trouble
Contents of
• Temperature signal circuit of boost pressure, temperature sensor detected low voltage.
trouble
Action of con-
• Fixes charge temperature value and continues operation.
troller
Problem that
appears on
• Engine protection function based on boost temperature does not work
machine
Related infor-
mation

TIM (male) Temperature Resistance
Defective boost pressure, 0°C 5.5 – 6.1 kz

1 temperature sensor [temper- 25°C 1.9 – 2.1 kz
ature signal system] Between (A) – (B)
40°C 1.1 – 1.2 kz
100°C 180 – 185 z
Between (A) – chas-
sis ground
2
cuit) – TIM (female) (A) and chassis ground tance 100 z
Possible causes Short circuit in wiring har- ing without turning starting switch ON.
and standard
3 ness Between CE01 (female) (23) – each of CE01
value in normal Resis- Min.
(with another wiring harness) (female) pins (With all wiring harness con-
state tance 100 kz
Connecting parts between boost pressure, temperature sensor –
engine wiring harness – engine controller may be defective. Check
Defective wiring harness them directly.
4
0°C 5.5 – 6.1 kz
5 Defective engine controller 25°C 1.9 – 2.1 kz
Between (23) – (47)
40°C 1.1 – 1.2 kz
100°C 180 – 185 z
sis ground
36 PC400, 450-7E0
Circuit diagram related to boost pressure, temperature sensor (combination sensor)
PC400, 450-7E0 37
Failure code [CA187] Sens Supply 2 Volt Low Error 1

Action code Failure code Sens Supply 2 Volt Low Error
Trouble
Contents of
• Low voltage error occurred in sensor power supply 2 (5V) circuit.
trouble
• 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.
Action of
controller • 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.
Problem that
appears on • Engine output lowers.
machine
Related
information

and standard
state
38 PC400, 450-7E0
PC400, 450-7E0 39
Failure code [CA221] Ambient Press Sens High Error 1

Action code Failure code Ambient Press Sens High Error
Trouble
Contents of
• High pressure error occurred in ambient pressure sensor circuit.
trouble
Action of
• Sets ambient pressure to default (52.44 kPa {0.52 kg/cm2}) and continues operation.
controller
Problem that
machine
Related
information

1
PAMB Voltage
Defective ambient pressure
2 sensor Between (1) – (3) Voltage 4.75 – 5.25 V
(Internal defect) Between (2) – (3) Signal
PAMB (female) (1) tance
Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal Between wiring harness of CE01 (female) (37) Resis-
Min. 1 Mz
state Ground fault in wiring harness – PAMB (female) (1) and chassis ground tance
4
(Short circuit with GND circuit) Between wiring harness of CE01 (female) (3) – Resis-
Min. 1 Mz
PAMB (female) (2) and chassis ground tance
Between wiring harness of CE01 (female) (38) Resis-
Min. 1 Mz
– PAMB (female) (3) and chassis ground tance
Resis-
PAMB (female) (1) and between CE01 Min. 1 Mz
tance
(female) (3) – PAMB (female) (2)
5
tance
Resis-
tance
6 Defective engine controller CE01 Voltage
Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38)
40 PC400, 450-7E0
Circuit diagram related to atmospheric pressure sensor
PC400, 450-7E0 41
Failure code [CA222] Ambient Press Sens Low Error 1

Action code Failure code Ambient Press Sens Low Error
Trouble
Contents of
• Low pressure error occurred in engine ambient pressure sensor circuit.
trouble
Action of
• Sets ambient pressure to default (52.44 kPa {0.51 kg/cm2}) and continues operation.
controller
Problem that
machine
Related
information

and standard
state
42 PC400, 450-7E0
Failure code [CA227] Sens Supply 2 Volt High Error 1

Action code Failure code Sens Supply 2 Volt High Error
Trouble
Contents of
• High voltage error occurred in sensor power supply 2 (5V) circuit.
trouble
• 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.
Action of
controller • 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.
Problem that
machine
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Bkup Speed Sensor G connector
Defective sensor Disconnect sensors Oil pressure sensor PFUEL connector
2 at right in order. If no
(Internal defect)
error code is dis- Change air temprera-
TIM connector
played, that sensor is ture sensor
defective. Charge air pressure
PIM connector
Possible causes sensor
and standard a Prepare with starting switch OFF, then carry out trouble-
value in normal
state Disconnection in wiring harness
defective contact in connector) – each sensor (female) tance
Max. 1 z
– each sensor (female) tance
Ground fault in wiring harness Wiring harness between CE01 (female) (37) Resis-
4 Min. 1 Mz
(Short circuit with GND circuit) – each sensor (female) and chassis ground tance
Min. 1 Mz
– each sensor (female) and chassis ground tance
PC400, 450-7E0 43

5
Possible causes (with another wiring harness) Wiring harness between CE01 (female) (37) Resis-
and standard – each sensor (female) and between CE01 Min. 1 Mz
tance
value in normal (female) (47) – each sensor (female)
state a Prepare with starting switch OFF, then turn starting
CE01 Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to sensor power supply 2 (5 V)
44 PC400, 450-7E0
Failure code [CA234] Eng Overspeed 1

Action code Failure code Eng Overspeed
Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded operating range.
trouble
Action of
• Limits fuel injection rate until it lowers in operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
• Method of reproducing failure code: Run engine at high idle.
information

Possible causes 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
and standard Machine may be used improperly. Teach operator proper using
value in normal 2 Improper use
method.
state
If causes 1 and 2 are not detected, engine controller may be defective.
PC400, 450-7E0 45
Failure code [CA238] Ne Speed Sens Supply Volt Error 1

Action code Failure code Ne Speed Sens Supply Volt Error
Trouble
Contents of
• High voltage error in engine Ne speed sensor power supply (5V) circuit.
trouble
Action of
• Controls the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine stops during operations. (when engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (when engine Bkup speed sensor is also defective)
machine
Related
information

Defective Ne speed sensor Disconnect sensors
(Internal defect)
error code is dis- Ne speed sensor NE connector
played, that sensor is
defective.
2 (Disconnection in wiring or Wiring harness between CE01 (female) (16) Resis-
Max. 1 z
– NE (female) (1) tance
Max. 1 z
Possible causes – NE (female) (2) tance
state
Ground fault in wiring harness Wiring harness between CE01 (female) (16) Resis-
3 Min. 1 Mz
(Short circuit with GND circuit) – NE (female) (1) and chassis ground tance
Min. 1 Mz
– NE (female) (2) and chassis ground tance
4
(with another wiring harness) Wiring harness between CE01 (female) (16) Resis-
– NE (female) (1) and between CE01 Min. 1 Mz
tance
(female) (48) – NE (female) (2)
CE01 Voltage
Between (16) – (48) 4.75 – 5.25 V
46 PC400, 450-7E0
Circuit diagram related to Ne speed sensor power supply
PC400, 450-7E0 47
Failure code [CA263] Fuel Temp Sensor High Error 1

Action code Failure code Fuel Temp Sensor High Error
Trouble
Contents of
• High temperature error occurred in fuel temperature sensor circuit.
trouble
Action of
• Fixes fuel temperature value at 90°C and continues operation.
controller
Problem that
appears on
machine
Related
information

Defective fuel temperature shooting without turning starting switch ON.
1 sensor
(Internal defect) TFUEL (male) Fuel temperature Resistance
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
and standard defective contact in connector) TFUEL (female) (A) tance
value in normal Wiring harness between CE01 (female) (47) – Resis-

Max. 1 z
state TFUEL (female) (B) tance
3 Min. 1 Mz
(Short circuit with GND circuit) TFUEL (female) (A) and chassis ground tance
CE01 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
48 PC400, 450-7E0
Circuit diagram related to fuel temperature sensor
PC400, 450-7E0 49
Failure code [CA265] Fuel Temp Sensor Low Error 1

Action code Failure code Fuel Temp Sensor Low Error
Trouble
Contents of
• Low temperature error occurred in fuel temperature sensor circuit.
trouble
Action of
• Fixes fuel temperature value at 90°C and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
50 PC400, 450-7E0
Failure code [CA271] IMV/PCV1 Short Error 1

Action code Failure code IMV/PCV1 Short Error
Trouble
Contents of
• Short circuit was detected in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump
PCV1 (male) Resistance
1 PCV1
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Possible causes switch ON and carry out troubleshooting.
and standard
value in normal Hot short in wiring harness Wiring harness between CE01 (female) (4) –
2 Voltage Max. 1 V
state (Short circuit with 24V circuit) PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
CE01 (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Circuit diagram related to supply pump PCV1
PC400, 450-7E0 51
Failure code [CA272] IMV/PCV1 Open Error 1

Action code Failure code IMV/PCV1 Open Error
Trouble
Contents of
• Open error was detected in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
defective contact in connector) PCV1 (female) (1) tance
PCV1 (female) (2) tance
and standard
Between wiring harness of CE01 (female) (4)
Ground fault in wiring harness – PCV1 (female) (1) and chassis ground and Resis- Max. 1
3 tance Mz
(Short circuit with GND circuit) chassis ground
Between wiring harness of CE01 (female) (5)
Resis- Max. 1
– PCV1 (female) (2) and chassis ground and
tance Mz
chassis ground
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
52 PC400, 450-7E0
PC400, 450-7E0 53
Failure code [CA273] PCV2 Short Error 1

Action code Failure code PCV2 Short Error
Trouble
Contents of
• Short circuit was detected in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump
PCV2 (male) Resistance
1 PCV2
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal Hot short in wiring harness Wiring harness between CE01 (female) (9) –
2 Voltage Max. 1 V
state (Short circuit with 24V circuit) PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
54 PC400, 450-7E0
Failure code [CA274] PCV2 Open Error 1

Action code Failure code PCV2 Open Error
Trouble
Contents of
• Open error was detected in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump shooting without turning starting switch ON.
1 PCV2
(Internal disconnection) PCV2 (male) Resistance
Between (1) – (2) 2.3 – 5.3 z
defective contact in connector) PCV2 (female) (1) tance
PCV2 (female) (2) tance
and standard
3 Min. 1 Mz
(Short circuit with GND circuit) PCV2 (female) (1) and chassis ground tance
Min. 1 Mz
PCV2 (female) (2) and chassis ground tance
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
PC400, 450-7E0 55
Failure code [CA322] Inj #1 (L/B#1) Open/Short Error 1
Action code Failure code Injector #1 (L/B#1) open/short circuit error

Trouble
Contents of
• Open or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Start engine
information

1 Defective No. 1 injector CN1 (male) Resistance
Between (1) – (2) Max. 2 z
Between (1) – chassis ground Min. 100 kz
ness
– CN1 (female) (1) tance
Max. 2 z
3
(Short circuit with GND cir- Wiring harness between CE01 (female) (45) Resis-
cuit) Max. 2 z
– CN1 (female) (1) and chassis ground tance
and standard
value in normal
state Between CE01 (female) (45) – each of CE01
Short circuit in wiring har- Resis- Min.
(female) pins (With all wiring harness con-
4 ness tance 100 kz
(with another wiring harness)
Between CE01 (female) (53) – each of CE01
Resis- Min.
tance 100 kz
Connecting parts between No. 1 injector – engine wiring harness –
engine controller may be defective. Check them directly.
connector
Defective other cylinder If the failure codes of other injectors are displayed, carry out trouble-
6
injectors or wiring harness shooting of them, too.
Between (45) – (53) Max. 2 z
56 PC400, 450-7E0
Circuit diagram related to injector No. 1
PC400, 450-7E0 57

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

ness
Max. 2 z
3
cuit) Max. 2 z
and standard
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
Between (46) – (60) Max. 2 z
58 PC400, 450-7E0
PC400, 450-7E0 59

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

ness
Max. 2 z
3
cuit) Max. 2 z
and standard
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
Between (55) – (52) Max. 2 z
60 PC400, 450-7E0
PC400, 450-7E0 61

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on • Combustion becomes irregular or engine hunts.
machine
Related
information

ness
Max. 2 z
3
cuit) Max. 2 z
and standard
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
Between (57) – (59) Max. 2 z
62 PC400, 450-7E0
PC400, 450-7E0 63

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

ness
Max. 2 z
3
cuit) Max. 2 z
and standard
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
Defective other cylinder If the failure codes of other injectors are displayed, carry out trou-
6
injectors or wiring harness bleshooting of them, too.
Between (54) – (51) Max. 2 z
64 PC400, 450-7E0
PC400, 450-7E0 65

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

ness
Max. 2 z
3
cuit) Max. 2 z
and standard
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
Between (56) – (58) Max. 2 z
66 PC400, 450-7E0
PC400, 450-7E0 67
SEN03601-02

© 2009 KOMATSU
All Rights Reserved
68
SEN03602-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089

65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
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 ......................................................................................... 12
Failure code [CA449] Rail Press Very High Error ......................................................................................... 14
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 18
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 20
Failure code [CA553] Rail Press High Error ................................................................................................. 22
Failure code [CA554] Rail Press Sensor In Range Error.............................................................................. 23
Failure code [CA559] Rail Press Low Error .................................................................................................. 24
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 30
PC400, 450-7E0 1
Failure code [CA757] All Persistent Data Lost Error ..................................................................................... 31

Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 32
Failure code [CA1228] EGR Valve Servo Error 1 ......................................................................................... 34
Failure code [CA1625] EGR Valve Servo Error 2 ......................................................................................... 35
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 36
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 41
Failure code [CA2271] EGR Valve Lift Sens High Error................................................................................ 42
Failure code [CA2272] EGR Valve Lift Sens Low Error ................................................................................ 44
Failure code [CA2351] EGR Valve Sol Current High Error ........................................................................... 46
Failure code [CA2352] EGR Valve Sol Current Low Error ............................................................................ 48
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 50
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 52
Failure code [D110KB] Battery Relay Drive Short Circuit ............................................................................. 54
Failure code [D196KA] Service Return Relay Open Circuit .......................................................................... 56
Failure code [D196KB] Service Return Relay Short Circuit .......................................................................... 58
Failure code [DA25KP] 5V Sensor 1 Power Abnormality.............................................................................. 60
Failure code [DA80MA] Auto. Lub. Abnormal. .............................................................................................. 62
2 PC400, 450-7E0
Failure code [CA342] Calibration Code Incompatibility 1

Action code Failure code Calibration code incompatibility
Trouble
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of con-
troller
Problem that
appears on • Normal operation, engine stopped, or start disabled
machine
Related infor-
mation

and standard 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
value in normal Engine controller may be defective. (Troubleshooting cannot be car-
state 2 Defective engine controller
ried out.)
PC400, 450-7E0 3
Failure code [CA351] Injectors Drive Circuit Error 1

Action code Failure code Injectors Drive Circuit Error
Trouble
Contents of
• There is error in injector drive circuit.
trouble
Action of
• Limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

Check the code (injector system error code) that is displayed simulta-
1 Defect in related system
neously. If another code is displayed, carry out troubleshooting for it.
Fuse may be defective. Check it directly.
2 Defective fuse No. 19 (If fuse is broken or circuit breaker is shut down, circuit probably has
ground fault.)
3 (Disconnection in wiring or Wiring harness between CE03 (female) (3) – Resis-
Max. 1 z
battery (+) tance
Possible causes defective contact in connector)
and standard Wiring harness between CE03 (female) (1) – Resis-
Max. 1 z
value in normal chassis ground tance
state a Prepare with starting switch OFF, then carry out trouble-
4 Min. 1 Mz
(Short circuit with GND circuit) battery (+) and chassis ground tance
Min. 1 Mz
CE03 Voltage
Between (3) – (1) 20 – 30 V
4 PC400, 450-7E0
Circuit diagram related to controller power supply
PC400, 450-7E0 5
Failure code [CA352] Sens Supply 1 Volt Low Error 1

Action code Failure code Sens Supply 1 Volt Low Error
Trouble
Contents of
• Low voltage error occurred in sensor power supply 1 (5V) circuit.
trouble
Action of
• Common rail pressure sensor limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
6 PC400, 450-7E0
PC400, 450-7E0 7
Failure code [CA386] Sens Supply 1 Volt High Error 1

Action code Failure code Sens Supply 1 Volt High Error
Trouble
Contents of
• High voltage error occurred in sensor power supply 1 (5V) circuit.
trouble
Action of
• Common rail pressure sensor limits output and continues operation (limits common rail pressure).
controller
Problem that
• Engine stops.
appears on
• Engine does not start easily.
machine
Related
information

Defective sensor Disconnect sensors
(Internal defect) Ambient pressure
error code is dis- PAMB connector
sensor
defective.
Max. 1 z
and standard
4 Min. 1 Mz
(Short circuit with GND circuit) PAMB (female) (1) and chassis ground tance
Min. 1 Mz
PAMB (female) (3) and chassis ground tance
5
tance
CE01 Voltage
Between (37) – (48) 4.75 – 5.25 V
8 PC400, 450-7E0
Circuit diagram related to sensor power supply 1 (5 V)
PC400, 450-7E0 9
Failure code [CA441] Battery Voltage Low Error 1

Action code Failure code Battery voltage low error
Trouble
Contents of trou-
• There is low voltage in controller power supply circuit.
ble
Action of control-
ler
Problem that
• Engine stops.
appears on
• Engine does not start easily.
machine
Related informa-
tion

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in each
case.
2 Defective battery voltage
Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)
Defective relay for engine
4 Replace relay (R23, R24) for engine controller with another relay
controller power supply
and perform reproducing operation. If “E” of failure code goes off at
this time, replaced relay is defective.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har-
Possible causes Wiring harness between F01-19 – R23, R24 Resis-
ness Max. 10 z
and standard (female) (3) tance
value in normal defective contact in connec- Wiring harness between R23, R24 (female) Resis-
Max. 10 z
state tor) (5) – CE03 (female) (3) tance
Max. 10 z
chassis ground (T11) tance
Ground fault in wiring har- without turning starting switch ON.
ness Wiring harness between F01-19 – R23, R24 Resis- Min.
6
(Short circuit with GND cir- (female) (3) and chassis ground tance 100 kz
cuit) Wiring harness between R23, R24 (female) Resis- Max.
(5) – CE03 (female) (3) and chassis ground tance 10 z
Between CE03 (female) (3) – CE03 (female) Resis- Min.
(1) pins (With battery terminal disconnected) tance 100 kz
Short circuit in wiring harness Between CE03 (female) (3) – each of CE02
7 Resis- Min.
(with another wiring harness) (female) pins (With battery terminal discon-
tance 100 kz
nected)
Resis- Min.
(female) pins (With battery terminal discon-
tance 100 kz
nected)
10 PC400, 450-7E0

Connecting parts between fuse No. 19 – machine wiring harness –
Defective wiring harness con-
Possible causes nector
and standard • Moisture or dirt in connector or defective insulation
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state
and start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
Circuit diagram related to engine controller power supply
PC400, 450-7E0 11
Failure code [CA442] Battery Voltage High Error 1
Action code Failure code Battery voltage high error

Trouble
Contents of
• There is high voltage (36 V or higher) in controller power supply circuit.
trouble
Action of con-
troller
Problem that
appears on • Engine may stop.
machine
Related infor-
mation

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry
and standard out troubleshooting.
value in normal 2 Defective alternator Alternator Engine speed Voltage
state
R terminal – chassis
ground
CE03 Voltage
Between (3) – (1) Max. 32 V
12 PC400, 450-7E0
Circuit diagram related to engine controller power supply
PC400, 450-7E0 13
Failure code [CA449] Rail Press Very High Error 1
Action code Failure code Common rail pressure very high error
Trouble
Contents of
• There is high pressure error (2) in common rail circuit.
trouble
Action of con-
• Limits output and continues operation.
troller
Problem that
machine
Related infor-
mation

There may be air in low pressure circuit. Check it directly according
to the following procedure.
1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
3) Check pressure pickup plug for leakage of fuel and air.
2 Air in low pressure circuit
• If this error occurs during air bleeding after the fuel filter was
replaced, air may remain in the fuel circuit. Keep running the
engine at low idle for about three minutes. As air is bled from the
fuel circuit, the engine speed will be stabilized, erasing the error
indication.
a For check of pressure in fuel low pressure circuit, see Testing
and adjusting, Checking fuel pressure.
• Measured in fuel filter outlet side.
During high idle
Pressure in fuel low- Max. 0.48 MPa
(if engine can be
pressure circuit {Max. 4.9 kg/cm2}
started)
Possible causes a For check of pressure in fuel low pressure circuit, see Testing
and standard and adjusting, Checking fuel pressure.
value in normal • Measured in fuel filter inlet and outlet sides.
state • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pres-
sure — Fuel filter outlet pressure
Defect in fuel low pressure Pressure drop in fuel Max. 0.14 MPa
3 During high idle
circuit parts low-pressure circuit {Max. 1.4 kg/cm2}
a For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
• Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 33.9 kPa
pressure During high idle
{Max. 254 mmHg}
(gear pump side)
a For check of fuel return circuit pressure, see Testing and
adjusting, Checking fuel pressure.
Fuel suction circuit
Max. 27.1 kPa
pressure During high idle
{Max. 203 mmHg}
(fuel connector side)
a Directly check for fuel leakage from fuel tube of fuel cooler, O-
4 Defective fuel cooler ring, seal washer damage, and check valve clogging or dam-
age.
14 PC400, 450-7E0

Defective common rail pres- Monitoring by
5 Monitoring code: 36400
sure sensor machine monitor
Common rail pres- While engine is 0 ± 0.39 MPa
sure stopped {0 ± 4 kg/cm2}
Defective O-ring of supply a Directly check that O-ring of supply pump actuator is not dam-
6
pump actuator aged.
a Prepare with starting switch OFF (INSITE connection), then
turn starting switch ON and carry out troubleshooting.
Monitoring by
Monitoring code: 36400
machine monitor
Common rail pres- While engine is 0 ± 0.39 MPa
Possible causes sure stopped {0 ± 4 kg/cm2}
Defective supply pump actu-
and standard 7 a Prepare with starting switch OFF (INSITE connection), then
ator
value in normal start engine and carry out troubleshooting.
state • Measured after one minute or more lapsed at idle.
Monitoring by
Monitoring code: 36400
machine monitor
Common rail pres- 1.96 MPa
During low idle
sure {20 kg/cm2}
The common rail fuel pressure sensor connector and supply pump
actuator may be defective. Check them directly.
connector
Defective engine controller ing without turning starting switch ON.
9
ground wiring harness CE03 (female) Resistance
Between (1) – chassis ground Max. 10 z
10 Defective supply pump If causes 1 – 9 are not detected, supply pump may be defective.
PC400, 450-7E0 15
Circuit diagram related to common rail pressure sensor and engine controller ground line
16 PC400, 450-7E0
PC400, 450-7E0 17
Failure code [CA451] Rail Press Sensor High Error 1
Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• There is high voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
troller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related infor-
mation

Defective sensor power sup- If failure code [CA227] is also indicated, carry out troubleshooting
1
ply 2 system for it first.
PFUEL Voltage
Defective common rail pres-
sure sensor
a Prepare with starting switch OFF, then keep starting switch
OFF and carry out troubleshooting.
Possible causes Disconnection in wiring har- Wiring harness between CE01 (female) (25) Resis-
and standard Max. 1 z
ness (Disconnection or – PFUEL (female) (2) tance
value in normal 3
defective contact of connec- Wiring harness between CE01 (female) (33) Resis-
state tor) Max. 1 z
– PFUEL (female) (1) tance
Max. 1 z
– PFUEL (female) (3) tance
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
4
CE01 Voltage
18 PC400, 450-7E0
Circuit diagram related to common rail pressure sensor
PC400, 450-7E0 19
Failure code [CA452] Rail Press Sensor Low Error 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
troller
Problem that
• Engine speed or output lowers.
appears on
• Engine does not start.
machine
Related infor-
mation

Defective sensor power sup- If failure code [CA187] is also indicated, carry out troubleshooting
1
ply 2 system for it first.
PFUEL Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- a Prepare with starting switch OFF, then turn starting switch ON
ness and carry out troubleshooting.
3
Possible causes
cuit) – PFUEL (female) (2) and chassis ground tance 100 kz
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state Short circuit in wiring har- ing without turning starting switch ON.
4 ness Wiring harness between CE01 (female) (25)
(with another wiring harness) – PFUEL (female) (2) and between CE01 Resis- Min.
tance 100 kz
(female) (47) – PFUEL (female) (1)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
20 PC400, 450-7E0
Circuit diagram related to common rail pressure sensor
PC400, 450-7E0 21
Failure code [CA553] Rail Press High Error 1

Action code Failure code Common rail pressure high error
Trouble
Contents of
• There is high pressure error (1) in common rail circuit.
trouble
Action of con-
troller
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor-
mation

Ground terminal may be connected defectively. Check following ter-
Possible causes minals directly.
and standard Defective connection of • Ground terminal of machine ((–) terminal of battery)
value in normal 2
ground terminal • Ground terminal of engine
state • Ground terminal of engine controller
• Ground terminal of starting motor
Defective O-ring of supply
3 O-ring of supply pump actuator may be broken. Check it directly.
pump actuator
22 PC400, 450-7E0
Failure code [CA554] Rail Press Sensor In Range Error 1

Action code Failure code Rail Press Sensor In Range Error
Trouble
— CA554 (Engine controller system)
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
• Limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
PC400, 450-7E0 23
Failure code [CA559] Rail Press Low Error 1

Action code Failure code Rail Press Low Error
Trouble
Contents of
• There is rail press very low error (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1 on
the next page. For check of pressure in fuel low pressure
Defect in low pressure cir- circuit, see Testing and adjusting, Checking fuel pressure.
3
cuit parts
Pressure in fuel low-pressure Min. 0.15 MPa
circuit {Min. 1.5 kg/cm2}
a For more information on troubleshooting, see Note 2 on
4 Clogged fuel filter, strainer
the next page.
Defective electrical system of Electrical system of supply pump PCV may be defective. Carry out trou-
5
supply pump PCV bleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
Possible causes Defective common rail pres- Mechanical system of common rail pressure sensor may be defec-
6
and standard sure sensor tive. Check whether wiring harness is damaged.
value in normal
a For check of leakage through pressure limiter, see Test-
state
7 Defective pressure limiter ing and adjusting, Checking fuel return rate and leakage.
Leakage through pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For check of limit return rate (spill) from injector, see Test-
ing and adjusting, Checking fuel return rate and leakage.
Limited return (spill) rate from
Speed in rated operation
injector
8 Defective 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
9 Defective supply pump 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 no-
pressure feed”.
24 PC400, 450-7E0
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 25
Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking failure code / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(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 — — —
4 Common rail pressure
*4 Rating or equivalent MPa
command
Common rail fuel pres-
*5 Rating or equivalent MPa
sure
Low idle CA — — —
Injection timing com-
*6 High idle CA — — —
mand
Rating or equivalent CA — — —
*7 Boost Pressure Rating or equivalent kPa — — —
Engine coolant tempera-
*8 Low idle °C — — —
ture
*9 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Func- Standard value Measured
Cut-out cylinder Check conditions Unit Good Bad
tion (Reference value) value
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
*10
Standard value Measured

C. Checking fuel circuit pressure Check conditions Unit Good Bad
(Reference value) value
Pressure in fuel low-pressure MPa Min. 0.15
6 High idle
circuit {kg/cm2} {Min. 1.5}
D. Checking strainer and filter Good Bad

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 Standard value Measured

Check conditions Unit Good Bad
rate (Reference value) value
11 Leakage through pressure limiter No-load, 1600 rpm cc/min Max. 10
Rating or equivalent 1,600 rpm cc/min 960 Speed:
Rating or equivalent 1,700 rpm cc/min 1,020
12 Return rate from injector Rating or equivalent 1,800 rpm cc/min 1,080 Return rate:
26 PC400, 450-7E0
*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 27
Failure code [CA689] Eng Ne Speed Sensor Error 1

Action code Failure code Eng Ne Speed Sensor Error
Trouble
Contents of
• There is error in engine Ne speed sensor circuit.
trouble
Action of
• Operates the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
information

Defective sensor power sup- If failure code [CA238] is displayed, carry out troubleshooting for it
1
ply system first.
Disconnection in wiring harness – NE (female) (1) Max. 1 z
tance
defective contact in connector) Wiring harness between CE01 (female) (48) Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Ground fault in wiring harness NE (female) (1) and chassis ground tance
3
Min. 1 Mz
NE (female) (2) and chassis ground tance
Possible causes
and standard Min. 1 Mz
NE (female) (3) and chassis ground tance
value in normal
Resis-
NE (female) (1) and between CE01 Min. 1 Mz
tance
4
tance
Resis-
tance
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.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
28 PC400, 450-7E0
Circuit diagram related to engine Ne speed sensor
PC400, 450-7E0 29
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1

Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of
• Controls the engine with signal from engine Ne speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
30 PC400, 450-7E0
Failure code [CA757] All Persistent Data Lost Error 1

Action code Failure code All Persistent Data Lost Error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related infor-
mation

and standard
state
PC400, 450-7E0 31
Failure code [CA778] Eng Bkup Speed Sensor Error 1

Action code Failure code Engine Bkup speed sensor error
Trouble
Contents of
• There is error in engine Bkup speed sensor circuit.
trouble
Action of
• Operates the engine with signal from engine Ne speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
information

1
Disconnection in wiring harness G (female) (1) Max. 1 z
tance
Max. 1 z
G (female) (2) tance
Max. 1 z
G (female) (3) tance
Min. 1 Mz
Ground fault in wiring harness G (female) (1) and chassis ground tance
3
Min. 1 Mz
G (female) (2) and chassis ground tance
Possible causes
and standard Min. 1 Mz
G (female) (3) and chassis ground tance
value in normal
Resis-
G (female) (1) and between CE01 (female) Min. 1 Mz
tance
(47) – G (female) (2)
4
tance
(26) – G (female) (3)
Resis-
tance
(26) – G (female) (3)
Defective sensor installation Bkup speed sensor may be installed defectively (improper clear-
5 or defective rotation sensor ance), or rotation sensor parts (in supply pump) may be defective.
parts Check them directly.
If causes 1 – 5 are not detected, engine Bkup speed sensor may be
Defective engine Bkup
6 defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
32 PC400, 450-7E0
Circuit diagram related to engine Bkup speed sensor
PC400, 450-7E0 33
Failure code [CA1228] EGR Valve Servo Error 1 1

Action code Failure code EGR Valve Servo Error 1
Trouble
Contents of
• There is EGR valve servo error (level 1).
trouble
Action of
• Performs open control.
controller
Problem that
machine
Related
information

a For measurement of EGR valve drive pressure, see Testing and
adjusting, “Measuring EGR valve and bypass valve drive pres-
sure”.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure
Low idle 1.18 MPa {12 kg/cm2}
High idle 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.
a For check of engine oil pressure, see Testing and adjust-
ing, Measuring engine oil pressure.
Possible causes
Engine Engine oil pressure
and standard Defective engine oil pressure
value in normal 3 Low idle 0.08MPa {0.8kg/cm2}
system (main circuit)
state 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.)
Oil pump or relief valve for EGR valve circuit may be defective.
4 Defective EGR valve oil pump
Check it directly.
Defective EGR valve oil Oil pressure supply piping for EGR valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
34 PC400, 450-7E0
Failure code [CA1625] EGR Valve Servo Error 2 1

Action code Failure code EGR Valve Servo Error 2
Trouble
Contents of
• There is EGR valve servo error (level 2).
trouble
Action of • Limits output and continues operation.
controller • Close EGR and bypass valves.
Problem that
machine
Related
information

and standard
state
PC400, 450-7E0 35
Failure code [CA1633] KOMNET Datalink Timeout Error 1

Action code Failure code KOMNET Datalink Timeout Error
Trouble
E0E CA1633 (Engine controller system)
Contents of
• There is error in KOMNET communication circuit with machine monitor.
trouble
Action of
• Operates in default mode or holds the state set when error occurred.
controller
Problem that
appears on
machine
Related
information

CE02 (female) (47), – CP02 (female) (22) tance
Max. 1 z
Wiring harness between P70 (female) (16) –
Resis-
Ground fault in wiring harness CE02 (female) (47), – CP02 (female) (22), – Min. 1 Mz
2 tance
(Short circuit with GND circuit) other related circuit and chassis ground
Resis-
Possible causes CE02 (female) (46), – CP02 (female) (32), – Min. 1 Mz
tance
and standard other related circuit and chassis ground
value in normal a Prepare with starting switch OFF, then turn starting
state switch ON and carry out troubleshooting.
Hot short (Short circuit with CE02 (female) (47), – CP02 (female) (22), – Voltage Max. 1 V
3
24V circuit) in wiring harness other related circuit and chassis ground
CE02 (female) (46), – CP02 (female) (32), – Voltage Max. 1 V
other related circuit and chassis ground
Defective CAN terminal shooting without turning starting switch ON.
4
resistance K02(male), K31(male) Resistance
Between (A) – (B) 108 – 132 z
Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller,
5 engine controller, or pump or pump controller may be defective. (Since trouble is in system,
controller troubleshooting cannot be carried out.)
36 PC400, 450-7E0
Circuit diagram related to CAN communication of pump controller
PC400, 450-7E0 37
Failure code [CA2185] Throt Sens Sup Volt High Error 1

Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of
• High voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
Action of
• Use a signal other than throttle sensor to set the throttle position for operations.
controller
Problem that
appears on
machine
Related
information

Defective fuel control dial Disconnect sensors
(Internal defect)
error code is dis- Fuel control dial P20 connector
defective.
Max. 1 z
Max. 1 z
Possible causes P20 (female) (3) tance
state
3 Min. 1 Mz
(Short circuit with GND circuit) P20 (female) (1) and chassis ground tance
Min. 1 Mz
4
P20 (female) (1) and between CE02 Min. 1 Mz
tance
(female) (23) – P20 (female) (3)
CE02 Voltage
Between (22) – (23) 4.75 – 5.25 V
38 PC400, 450-7E0
Circuit diagram related to fuel control dial throttle sensor
PC400, 450-7E0 39
Failure code [CA2186] Throt Sens Sup Volt Low Error 1

Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of
• Low voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
Action of
• Use a signal other than throttle sensor to set the throttle position for operations.
controller
Problem that
appears on
machine
Related
information

and standard
state
40 PC400, 450-7E0
Failure code [CA2249] Rail Press Very Low Error 1

Action code Failure code Rail Press Very Low Error
Trouble
Contents of
• There is rail press very low error (level 2).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
PC400, 450-7E0 41
Failure code [CA2271] EGR Valve Lift Sens High Error 1

Action code Failure code EGR Valve Lift Sens High Error
Trouble
Contents of
• High error occurred in EGR valve lift sensor circuit.
trouble
Problem that
machine
Related
information

1
SEGR Voltage
Defective EGR valve lift sensor
(Internal defect)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
SEGR (female) (1) tance
Max. 1 z
SEGR (female) (2) tance
Possible causes Wiring harness between CE01 (female) (19) – Resis-

Max. 1 z
and standard SEGR (female) (3), (4) tance
Min. 1 Mz
Ground fault in wiring harness SEGR (female) (1) and chassis ground tance
4
Min. 1 Mz
SEGR (female) (2) and chassis ground tance
Min. 1 Mz
SEGR (female) (3), (4) and chassis ground tance
Resis-
SEGR (female) (1) and between CE01 Min. 1 Mz
tance
(female) (47) – SEGR (female) (2)
5
tance
(female) (19) – SEGR (female) (3), (4)
Resis-
tance
(female) (19) – SEGR (female) (3), (4)
42 PC400, 450-7E0

Possible causes a Prepare with starting switch OFF, then turn starting
and standard switch ON or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller
state CE01 Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid and lift sensor
PC400, 450-7E0 43
Failure code [CA2272] EGR Valve Lift Sens Low Error 1

Action code Failure code EGR Valve Lift Sens Low Error
Trouble
Contents of
• Low error occurred in EGR valve lift sensor circuit.
trouble
Problem that
machine
Related
information

and standard
state
44 PC400, 450-7E0
PC400, 450-7E0 45
Failure code [CA2351] EGR Valve Sol Current High Error 1

Action code Failure code EGR Valve Sol Current High Error
Trouble
Contents of
• High current error occurred in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

Defective EGR valve solenoid shooting without turning starting switch ON.
1
(Internal defect) EGR (male) Resistance
Between (1) – (2) 10 – 21 z
defective contact in connector) EGR (female) (1) tance
Max. 1 z
– EGR (female) (2) tance
Possible causes shooting without turning starting switch ON.
and standard
value in normal Ground fault in wiring harness Wiring harness between CE01 (female) (22) – Resis-
3 Min. 1 Mz
state (Short circuit with GND circuit) EGR (female) (1) and chassis ground tance
Min. 1 Mz
– EGR (female) (2) and chassis ground tance
Hot short in wiring harness Wiring harness between CE01 (female) (22) –
4 Voltage Max. 1 V
(Short circuit with 24V circuit) EGR (female) (1) and chassis ground
Voltage Max. 1 V
– EGR (female) (2) and chassis ground
Between (22) – (11) 10 – 21 z
46 PC400, 450-7E0
Circuit diagram related to EGR valve solenoid and lift sensor
PC400, 450-7E0 47
Failure code [CA2352] EGR Valve Sol Current Low Error 1

Action code Failure code EGR Valve Sol Current Low Error
Trouble
Contents of
• Low current error occurred in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
48 PC400, 450-7E0
PC400, 450-7E0 49
Failure code [CA2555] Grid Htr Relay Volt Low Error 1

Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of
• Open error was detected in intake air heater relay circuit
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
• Heater relay drive conditions vary depending on applicable machine.
information

Defective grid heater relay shooting without turning starting switch ON.
1
(Internal defect) R18 (male) Resistance
Between (1) – (2) 200 – 400 z
defective contact in connector) R18 (female) (1) tance
Possible causes Wiring harness between CE02 (female) (42) – Resis-
Max. 1 z
and standard R18 (female) (2) tance
3 Min. 1 Mz
(Short circuit with GND circuit) R18 (female) (1) and chassis ground tance
Min. 1 Mz
R18 (female) (2) and chassis ground tance
4 Defective engine controller CE02 Heater relay Voltage
Operating condition Max. 1 V
Between (40) – (42)
Stop condition 20 – 30 V
50 PC400, 450-7E0
Circuit diagram related to engine preheater
PC400, 450-7E0 51
Failure code [CA2556] Grid Htr Relay Volt High Error 1

Action code Failure code Grid heater relay volt high error
Trouble
Contents of
• Disconnection was detected in intake air heater relay circuit.
trouble
Action of con-
troller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related infor-
mation

and standard
state
52 PC400, 450-7E0
PC400, 450-7E0 53
Failure code [D110KB] Battery Relay Drive Short Circuit 1

Action code Failure code Battery Relay Drive Short Circuit
Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not start.
machine
Related • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
information (Code 03700: Controller Output)

Battery relay Continuity/Resistance
Defective battery relay
1 Between R02 (terminal BR) –
(Internal short circuit) There is continuity
R01 (terminal E)
Between R02 (terminal BR) –
Min. 1 Mz
chassis ground
Possible causes
state 2
(Short circuit with GND circuit) Wiring harness between CP03 (female) (4) – Resis-
D01 – J01 – A02 – R02 (terminal BR) and Min. 1 Mz
tance
chassis ground
Turn starting switch
3 Defective pump controller CP03 Voltage
OFF.
Between (4) – 20 – 30 V
ON o OFF
chassis ground (4 – 7 sec.)
54 PC400, 450-7E0
Circuit diagram related to battery relay drive
PC400, 450-7E0 55
Failure code [D196KA] Service Return Relay Open Circuit 1

Action code Failure code Service Return Relay Open Circuit.
Trouble
— D196KA (Pump controller system)
Contents of • When service return relay circuit was disconnected with GND (when output was turned OFF), 24V
trouble was not generated.
Action of • None in particular.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• 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.
Related
When service return solenoid may be in defective operation, check the power source,
information
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)

1 Defective fuse No.2 If fuse is burnt, circuit probably has ground fault.
Defective service return relay shooting without turning starting switch ON.
2
(Internal disconnection) R20 (male) Resistance
Between (1) – (2) 100 – 500 z
Wiring harness between CP02 (female) (8) – Resis-
R20 (female) (2) tance
Wiring harness between R20 (female) (1) – Resis-
J03 – F01-2 outlet tance
and standard
Ground fault in wiring harness Wiring harness between CP02 (female) (8) – Resis-
4 Min. 1 Mz
(Short circuit with GND circuit) R20 (female) (2) and chassis ground tance
Min. 1 Mz
J03 – F01-2 outlet and chassis ground tance
CP02 Working mode Voltage
5 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – selected
chassis ground When B-mode is
Max. 1 V
selected
56 PC400, 450-7E0
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-7E0 57
Failure code [D196KB] Service Return Relay Short Circuit 1

Action code Failure code Service Return Relay Short Circuit
Trouble
— D196KB (Pump controller system)
Contents of • When service return relay circuit was connected to GND (when output was turned ON), abnormal
trouble current flowed.
Action of • Turns output to service return relay circuit OFF.
Problem that
appears on • Hydraulic circuit for attachment does not change to single operation circuit.
machine
• 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.
Related
When service return solenoid may be in defective operation, check the power source, wiring har-
information
ness, 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.

Defective service return relay shooting without turning starting switch ON.
1
(internal short circuit) R20 (male) Resistance
Between (1) – (2) 100 – 500 z
Possible causes Hot short (Short circuit with switch ON and carry out troubleshooting.
2
and standard 24V circuit) in wiring harness Wiring harness between CP02 (female) (8) –
value in normal Voltage Max. 1 V
R20 (female) (2) and chassis ground
state
3 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – selected
chassis ground When B-mode is
Max. 1 V
selected
58 PC400, 450-7E0
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-7E0 59
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 1

Action code Failure code 5V Sensor 1 Power Abnormality
Trouble
E02 DA25KP (Pump controller system)
Contents of
• Abnormal current flowed in pressure sensor power supply (5V) circuit.
trouble
• Turns output to power supply (5V) circuit OFF.
Action of
• Even if phenomenon of failure disappears, system does not reset itself until starting switch is turned
controller
OFF.
Problem that
• Signal of pressure sensor is not input normally.
appears on
• Pressure sensor failure code is displayed at the same time.
machine
Related
information

a Disconnect connector with starting switch OFF, then turn
starting switch ON and carry out troubleshooting.
F pump pressure
P25 connector
sensor
Defective pressure sensor Disconnect sensors R pump pressure
1 at right in order. If no P26 connector
(Internal short circuit) sensor
error code is dis-
played, that sensor is Bucket CURL press
P01 connector
defective. sensor
Arm IN pressure
P04 connector
sensor
Possible causes
and standard Wiring harness between CP01 (female) (22) –
Resis-
value in normal A03 – P25 (female) (3) and chassis ground Min. 1 Mz
tance
state [F pump pressure sensor system]
Wiring harness between CP01 (female) (22) –
Ground fault in wiring harness A03 – P26 (female) (3) and chassis ground Resis-
Min. 1 Mz
2 tance
(Short circuit with GND circuit) [R pump pressure sensor system]
Resis-
A03 – P01 (female) (3) and chassis ground Min. 1 Mz
tance
[Bucket CURL pressure sensor system]
Resis-
A03 – P04 (female) (3) and chassis ground Min. 1 Mz
tance
[Arm IN pressure sensor system]
3 Defective pump controller
CP01 Voltage
Between (22) – (10) 4.5 – 5.5 V
60 PC400, 450-7E0
Circuit diagram related to pressure sensor power supply of pump controller
PC400, 450-7E0 61
Failure code [DA80MA] Auto. Lub. Abnormal. 1

a This failure code is displayed only when automatic lubrication equipment is installed.
62 PC400, 450-7E0
PC400, 450-7E0 63
SEN03602-01

© 2008 KOMATSU
All Rights Reserved
64
SEN03603-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
Failure code [DA2RMC] Pump Comm. Abnormality ....................................................................................... 4
Failure code [DA2SKQ] Model Selection Abnormality .................................................................................... 6
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................................... 8
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit ................................................................................. 10
Failure code [DHPAMA] F Pump Press Sensor Abnormality ........................................................................ 12
Failure code [DHPBMA] R Pump Press Sensor Abnormality ....................................................................... 14
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality .............................................................. 16
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.......................................................... 18
Failure code [DW43KA] Travel Speed Sol. Open Circuit .............................................................................. 20
Failure code [DW43KB] Travel Speed Sol. Short Circuit .............................................................................. 22
Failure code [DW45KA] Swing Brake Sol. Open Circuit ............................................................................... 24
Failure code [DW45KB] Swing Brake Sol. Short Circuit ............................................................................... 28
Failure code [DW91KA] Travel Junction Sol. Open Circuit ........................................................................... 30
Failure code [DW91KB] Travel Junction Sol. Short Circuit ........................................................................... 32
PC400, 450-7E0 1
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit.............................................................................. 34

Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit ............................................................................. 36
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit............................................................................. 38
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit ............................................................................. 40
Failure code [DXA0KA] PC-EPC Sol. Open Circuit ...................................................................................... 42
Failure code [DXA0KB] PC-EPC Sol. Short Circuit....................................................................................... 44
Failure code [DXE0KA] LS-EPC Sol. Open Circuit ....................................................................................... 46
Failure code [DXE0KB] LS-EPC Sol. Short Circuit ....................................................................................... 48
Failure code [DXE4KA] Service Current EPC Open Circuit.......................................................................... 50
Failure code [DXE4KB] Service Current EPC Short Circuit .......................................................................... 51
Failure code [DY20KA] Wiper Working Abnormality ..................................................................................... 52
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................................... 54
Failure code [DY2CKB] Washer Drive Short Circuit...................................................................................... 56
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................. 58
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit............................................................................... 60
2 PC400, 450-7E0
PC400, 450-7E0 3
Failure code [DA2RMC] Pump Comm. Abnormality 1

Action code Failure code Pump Comm. Abnormality
Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine mon-
trouble itor and engine controller.
Action of • Fix engine output to E-mode, and limit pump absorption torque to about 80%.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

defective contact in connector) CE02 (female) (47), – CP02 (female) (22) tance
Max. 1 z
Ground fault in wiring harness CE02 (female) (47), – CP02 (female) (22), – Resis-
2 Min. 1 Mz
(Short circuit with GND circuit) other related circuit and chassis ground tance

Resis-
tance
value in normal a Prepare with starting switch OFF, then turn starting
state switch ON and carry out troubleshooting.
3
4
resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
5 engine controller, or pump or pump controller may be defective.
controller (Since trouble is in system, troubleshooting cannot be carried out.)
4 PC400, 450-7E0
Circuit diagram related to CAN communication of pump controller
PC400, 450-7E0 5
Failure code [DA2SKQ] Model Selection Abnormality 1

Action code Failure code Model Selection Abnormality
Trouble
— DA2SKQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC400) and continues control.
Problem that
appears on • None in particular.
machine
• Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Related
• Input of model selection signal (ON/OFF) can be checked with monitoring function.
information
(Code 02200: Switch Input 2)

Defective model selection shooting without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or
short circuit) Between (2), (3), (7) – (8) Max. 1 z
Between (1), (4), (5), (6) – (8) Min. 1 Mz
Max. 1 z
S30 (male) (4) and chassis ground tance
Disconnection in wiring harness S30 (male) (3) Max. 1 z
tance
defective contact in connector) Wiring harness between CP02 (female) (27) – Resis-
Max. 1 z
S30 (male) (2) tance
Max. 1 z
Possible causes
and standard Wiring harness between S30 (male) (8) – Resis-
Max. 1 z
value in normal J05 – A01 – chassis ground tance
Min. 1 Mz
3 Min. 1 Mz
(Short circuit with GND circuit) S30 (male) (7) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
aPrepare with starting switch OFF, then turn starting switch ON and
CP02 Voltage
4 Defective pump controller Between (7), (37) – chassis
20 – 30 V
ground
Between (13), (17), (27) –
Max. 1 V
chassis ground
6 PC400, 450-7E0
Circuit diagram related to model selection connector of pump controller
PC400, 450-7E0 7
Failure code [DAFRMC] Monitor Comm. Abnormality 1

Action code Failure code Monitor Comm. Abnormality
Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of • Fix engine output to E-mode, and limit pump absorption torque to about 80%.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

defective contact in connector) CE02 (female) (47), – CP02 (female) (22) tance
Wiring harnesses between P70 (female) (15) – Resis-
Max. 1 z
CE02 (male)(46) and – CP02 (females) (32) tance
Ground fault in wiring harness CE02 (female) (47), – CP02 (female) (22), – Resis-
Min. 1 Mz
2 tance
(Short circuit with GND circuit) other related circuit and chassis ground
Resis-
tance
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
3
4
resistance K02(male), K31(male) Resistance
Between (A) – (B) 120 ± 12 z
5 engine controller, or pump or pump controller may be defective. (Since trouble is in system,
controller troubleshooting cannot be carried out.)
8 PC400, 450-7E0
Circuit diagram related to CAN communication of machine monitor
PC400, 450-7E0 9
Failure code [DGH2KB] Hydr Oil Sensor Short Circuit 1

User code Failure code Hydraulic oil temperature sensor short circuit
Trouble
— DGH2KB (Pump controller system)
Contents of
• Ground fault was detected in hydraulic oil temperature sensor circuit.
trouble
Action of • Fixes hydraulic oil temperature value at 40°C and continues operation.
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from
appears on
top of white range (bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related infor-
(Code: 04402 Hydraulic oil temperature sensor voltage)
mation

Defective hydraulic oil tem-
1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 kz
Between (2) – chassis ground Min. 1 Mz
Possible causes
and standard Ground fault in wiring har- without turning starting switch ON.
value in normal 2 ness (Short circuit with GND
state circuit) Wiring harness between C01 (female) (29) – Resis-
Min. 1 Mz
3 Defective pump controller C01 (female) Resistance
Between (29) – (46) 3.5 – 90 kz
Circuit diagram related to hydraulic oil temperature sensor
10 PC400, 450-7E0
PC400, 450-7E0 11
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1

Action code Failure code F Pump Press Sensor Abnormality
Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage from F pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes F pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on • No automatic gear shifting
machine
a If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure
Related sensor will be broken. Accordingly, take extreme care when checking.
information • Input from F pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01112: F pump pressure)

Defective sensor power sup- If error code [DA25KP] is also displayed, carry out troubleshooting
1
ply system for it first.
Defective F pump pressure
2 sensor P25 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5V
Between (2) – (1) 0.5 – 4.5V
Disconnection in wiring harness A03 – P25 (female) (3) Max. 1 z
tance
Max. 1 z
A06 – P25 (female) (1) tance
Possible causes
value in normal
Ground fault in wiring harness shooting without turning starting switch ON.
4
Min. 1 Mz
A06 – P25 (female) (2) and chassis ground tance
Hot short (Short circuit with Wiring harness between CP01 (female) (22) –
5 Voltage Max. 1 V
24V circuit) in wiring harness A03 – P25 (female) (3) and chassis ground
Voltage Max. 1 V
A06 – P25 (female) (2) and chassis ground
Between (22) – (10) 4.5 – 5.5V
Between (8) – (10) 0.5 – 4.5V
12 PC400, 450-7E0
Circuit diagram related to F pump pressure sensor of pump controller
PC400, 450-7E0 13
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1

Action code Failure code R Pump Press Sensor Abnormality
Trouble
— DHPBMA (Pump controller system)
Contents of
• Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
information • Input from R pump pressure sensor (pressure) can be checked with monitoring function.
(Code 01113: R pump pressure

1
Defective R pump pressure
2 sensor P26 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5V
Between (2) – (1) 0.5 – 4.5V
tance
Max. 1 z
Possible causes
value in normal
4
Min. 1 Mz
A06 – P26 (female) (2) and chassis ground tance
5 Voltage Max. 1 V
Voltage Max. 1 V
Between (22) – (10) 4.5 – 5.5V
Between (2) – (10) 0.5 – 4.5V
14 PC400, 450-7E0
Circuit diagram related to R pump pressure sensor of pump controller
PC400, 450-7E0 15
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 1

Action code Failure code Arm Curl PPC Press Sensor Abnormality
Trouble
— DHS3MA (Pump controller system)
Contents of
• Signal voltage from arm curl PPC pressure sensor is below 0.3 V or above 4.72 V.
trouble
Action of • Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
information • Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm Curl PPC Pressure

1
Defective arm curl PPC pres- P04 Voltage
2
sure sensor (Internal defect)
Between (3) – (1) 4.5 – 5.5V
Between (2) – (1) 0.5 – 4.5V
tance
Max. 1 z
Possible causes
value in normal
Ground fault in wiring har- shooting without turning starting switch ON.
4 ness
Min. 1 Mz
5 Voltage Max. 1 V
Voltage Max. 1 V
Between (22) – (10) 4.5 – 5.5V
Between (19) – (10) 0.5 – 4.5V
16 PC400, 450-7E0
Circuit diagram related to arm curl PPC pressure sensor of pump controller
PC400, 450-7E0 17
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1

Action code Failure code Bucket Curl PPC Press Sensor Abnormality
Trouble
— DHS4MA (Pump controller system)
Contents of
• Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
aIf 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure
information • Input from the pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC Pressure)

1
Defective bucket curl PPC
2 pressure sensor (Internal P01 Voltage
defect) Between (3) – (1) 4.5 – 5.5V
Between (2) – (1) 0.5 – 4.5V
tance
Max. 1 z
Possible causes
value in normal
4
Min. 1 Mz
5 Voltage Max. 1 V
Voltage Max. 1 V
P01 (female) (2) and chassis ground
Between (22) – (10) 4.5 – 5.5V
Between (13) – (10) 0.5 – 4.5V
18 PC400, 450-7E0
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC400, 450-7E0 19
Failure code [DW43KA] Travel Speed Sol. Open Circuit 1

Action code Failure code Travel Speed Sol. Open Circuit
Trouble
— DW43KA (Pump controller system)
Contents of
• No current flows travel speed solenoid circuit as power is turned on.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
• Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be
information
sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for
failure code [DW43KB].)

Travel Speed Sol. Disc. shooting without turning starting switch ON.
1
(Internal disconnection) V04 (male) Resistance
Between (1) – (2) 20 – 60 z
defective contact in connector) A05 – V04 (female) (2) tance
and standard
value in normal Wiring harness between V04 (female) (1) – Resis-
Max. 1 z
state chassis ground tance
3
Min. 1 Mz
A05 – V04 (female) (2) and chassis ground tance
CP03 (female) Resistance
Between (27) – chassis ground 20 – 60 z
20 PC400, 450-7E0
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-7E0 21
Failure code [DW43KB] Travel Speed Sol. Short Circuit 1

Action code Failure code Travel Speed Sol. Short Circuit
Trouble
— DW43KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel speed solenoid circuit.
trouble
Action of • Turns output to travel speed solenoid circuit OFF.
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
Related • Operating condition of travel speed solenoid (ON/OFF) can be checked with the monitoring function.
information (Code 02300: Solenoid 1)

Travel Speed Sol. Disc.
1 (Internal short circuit or V04 (male) Resistance
ground fault) Between (1) – (2) 20 – 60 z
Possible causes
and standard
value in normal Hot short (Short circuit with switch ON and carry out troubleshooting.
2
state 24V circuit) in wiring harness Wiring harness between CP03 (female) (27) –
Voltage Max. 1 V
A05 – V04 (female) (2) and chassis ground
3 Defective pump controller CP03 Travel speed Voltage
Between (27) – Lo Max. 1 V
chassis ground Hi + Travel operation 20 – 30 V
22 PC400, 450-7E0
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-7E0 23
Failure code [DW45KA] Swing Brake Sol. Open Circuit 1

Action code Failure code Swing Brake Sol. Open Circuit
Trouble
E03 DW45KA (Pump controller system)
Contents of
• No current flows at output to swing brake solenoid circuit.
trouble
Problem that
appears on • Machine cannot swing.
machine
• 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
Related release switch in release position (Swing holding brake does not work, however, when machine stops).
information • Turn both of swing lock and emergency swing release switches OFF during troubleshooting.

Defective swing holding shooting without turning starting switch ON.
1 brake solenoid (Internal dis-
connection) V05 (male) Resistance
Between (1) – (2) 20 – 60 z
Defective swing lock switch S04 (female) Switch Resistance
2
(Internal disconnection)
OFF Max. 1 z
Between (3) – (4)
LOCK Min. 1 Mz
Defective assembled-type shooting without turning starting switch ON.
3 diode D01
D01 (male) Digital circuit tester Continuity
Possible causes Between (7) – (3) Diode mode There is continuity
value in normal
state
Max. 1 z
D01 (female) (7) tance
Wiring harness between D01 (female) (3) – Resis-
J02 – S04 (male) (3) tance
Wiring harness between S04 (male) (4) – Resis-
Max. 1 z
A05 – V05 (female) (2) tance
Wiring harness between V05 (female) (1) – Resis-
Max. 1 z
CP03 (female) (3), (13), (23) tance
5
(Short circuit with GND circuit) D01 – J02 – H06 – S04 (male) (3) and chas- tance
Min. 1 Mz
sis ground
Wiring harness between V05 (female) (2) – A05 – Resis-
Min. 1 Mz
H06 – S04 (male) (4) and chassis ground tance
24 PC400, 450-7E0
Possible causes a Prepare with starting switch OFF, then carry out trouble-
and standard shooting without turning starting switch ON.
value in normal 6 Defective pump controller CP03 (female) Resistance
Disconnect D01 and
state
Between (37) – connect pins (3) and (7)
on female side directly. 20 – 60 z
chassis ground
PC400, 450-7E0 25
Circuit diagram related to swing holding brake solenoid of pump controller
26 PC400, 450-7E0
PC400, 450-7E0 27
Failure code [DW45KB] Swing Brake Sol. Short Circuit 1

Action code Failure code Swing Brake Sol. Short Circuit
Trouble
E03 DW45KB (Pump controller system)
Contents of
• Abnormal current flowed at output to swing brake solenoid circuit.
trouble
Action of • Turns output to swing brake solenoid circuit OFF.
Problem that
appears on • Machine cannot swing.
machine
• Operating condition of swing brake solenoid (ON/OFF) can be checked with monitoring function.
Related (Code 02300: Solenoid 1)
information • 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).

Defective swing holding
1 brake solenoid (Internal short V05 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 z
2 diode D01
D01 (male) Resistance
Possible causes (Internal short circuit)
and standard Between (3) – (7) Min. 1 Mz
value in normal aPrepare with starting switch OFF, then turn starting switch ON and
state carry out troubleshooting.
3 Voltage Max. 1 V
24V circuit) in wiring harness D01 – H06 – S04 (male) (3) and chassis ground
Wiring harness between V05 (female) (2) – A05 –
Voltage Max. 1 V
H06 – S04 (male) (4) and chassis ground
4 Defective pump controller CP03 Swing lever Voltage
Between (37) – When at neutral Max. 1 V
chassis ground At swing 20 – 30 V
28 PC400, 450-7E0
Circuit diagram related to swing holding brake solenoid of pump controller
PC400, 450-7E0 29
Failure code [DW91KA] Travel Junction Sol. Open Circuit 1

Action code Failure code Travel Junction Sol. Open Circuit
Trouble
— DW91KA (Pump controller system)
Contents of
• No current flows at output to travel junction valve solenoid circuit.
trouble
Problem that
appears on • Turning from operating travel steering becomes difficult.
machine
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related
information

Defective travel junction shooting without turning starting switch ON.
1 solenoid
V02 (male) Resistance
Between (1) – (2) 20 – 60 z
Disconnection in wiring harness Wiring harness between CP03 (female) (7) – Resis-
Max. 1 z
Possible causes 2 (Disconnection in wiring or A05 – V02 (female) (2) tance
Wiring harness between V02 (female) (1) –
value in normal Resis-
A05 – CP03 (female) (3), (13), Max. 1 z
state tance
(23) – chassis ground
3
Min. 1 Mz
Between (7) – (3), (13), (23) 20 – 60 z
30 PC400, 450-7E0
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-7E0 31
Failure code [DW91KB] Travel Junction Sol. Short Circuit 1

Action code Failure code Travel Junction Sol. Short Circuit
Trouble
— DW91KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of • Turns output to travel junction solenoid OFF.
Problem that
appears on • Hard to turn when operating travel steering.
machine
Related • Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.

Defective travel junction shooting without turning starting switch ON.
solenoid V02 (male) Resistance
1
(Internal short circuit or
Possible causes
Prepare with starting switch OFF, then turn starting switch ON and
and standard
value in normal Hot short (Short circuit with carry out troubleshooting.
2
Voltage Max. 1 V
3 Defective pump controller CP03 Travel lever Voltage
Between (7) – (3), At straight advance Max. 1 V
(13), (23) At steering 20 – 30 V
32 PC400, 450-7E0
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-7E0 33
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit 1

Action code Failure code Merge-divider Sol. Open Circuit
Trouble
— DWJ0KA (Pump controller system)
Contents of
• No current flows at output to merge-divider solenoid circuit.
trouble
Problem that
appears on • Independent operation speed of work equipment and swing machinery is re high in lifting mode (L).
machine
• Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Related
• Solenoid detects disconnection when output is turned on. To confirm the modification after repair, be
information
failure code [DWJ0KB].)

Defective merge-divider shooting without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 z
Disconnection in wiring harness Wiring harness between CP03 (female) (17) – Resis-
Max. 1 z
Possible causes 2 (Disconnection in wiring or A05 – V03 (female) (2) tance
Wiring harness between V03 (female) (1) –
value in normal Resis-
A05 – CP03 (female) (3), (13), (23) – chassis Max. 1 z
state tance
ground
3
Min. 1 Mz
Between (17) – (3), (13), (23) 20 – 60 z
34 PC400, 450-7E0
Circuit diagram related to merge-divider solenoid of pump controller
PC400, 450-7E0 35
Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit 1

Action code Failure code Merge-Divider Sol. Short Circuit
Trouble
— DWJ0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to merge-divider solenoid circuit.
trouble
Action of • Turns output to merge-divider solenoid circuit OFF.
Problem that
appears on • Single operation speed of work equipment and swing is re high in lifting mode (L).
machine
Related • Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.

Defective merge-divider shooting without turning starting switch ON.
solenoid
1 V03 (male) Resistance
Possible causes Prepare with starting switch OFF, then turn starting switch ON and
and standard Hot short (Short circuit with carry out troubleshooting.
value in normal 2
24V circuit) in wiring harness Wiring harness between CP03 (female) (17) –
state Voltage Max. 1 V
CP03 Travel lever Voltage
When at neutral Max. 1 V
Between (17) – (3),
(13), (23) When either side is
20 – 30 V
operated
36 PC400, 450-7E0
Circuit diagram related to merge-divider solenoid of pump controller
PC400, 450-7E0 37
Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit 1

Action code Failure code 2-stage Relief Sol. Open Circuit
Trouble
— DWK0KA (Pump controller system)
Contents of
• No current flows at output to 2-stage relief solenoid circuit.
trouble
Problem that
appears on • Power maximizing function does not work.
machine
• Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related
information
failure code [DWK0KB].)

Defective 2-stage relief sole- shooting without turning starting switch ON.
1 noid
Between (1) – (2) 20 – 60 z
defective contact in connector) A05 – V08 (female) (2) tance
and standard
value in normal Wiring harness between V08 (female) (1) – Resis-
Max. 1 z
state A05 – CP03 (female) (3), (13), (23) tance
3
Min. 1 Mz
Between (28) – chassis ground 20 – 60 z
38 PC400, 450-7E0
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400, 450-7E0 39
Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit 1

Action code Failure code 2-stage Relief Sol. Short Circuit
Trouble
— DWK0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of • Turns output to 2-stage relief solenoid circuit OFF.
Problem that
appears on • Power maximizing function does not work.
machine
Related • Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.

Defective 2-stage relief sole- shooting without turning starting switch ON.
noid V08 (male) Resistance
1
Possible causes a Prepare with starting switch OFF, then turn starting
and standard Hot short (short circuit with switch ON and carry out troubleshooting.
value in normal 2
state Voltage Max. 1 V
When L-mode is not
Between (28) – Max. 1 V
selected
chassis ground
L-mode is selected 20 – 30 V
40 PC400, 450-7E0
Circuit diagram related to 2-stage relief solenoid of pump controller
PC400, 450-7E0 41
Failure code [DXA0KA] PC-EPC Sol. Open Circuit 1

Action code Failure code PC-EPC Sol. Open Circuit
Trouble
E02 DXA0KA (Pump controller system)
Contents of
• No current flows at output to PC-EPC solenoid circuit.
trouble
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
Related
• If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
information
operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)

Defective PC-EPC solenoid shooting without turning starting switch ON.
1
Between (1) – (2) 7 – 14 z
S21 Switch Resistance
Defective emergency pump
2 drive switch (Internal discon- OFF Max. 1 z
Between (2) – (3)
nection) ON Min. 1 Mz
OFF Max. 1 z
Between (5) – (6)
ON Min. 1 Mz
and standard
value in normal Wiring harness between CP03 (female) (16) – Resis-
Max. 1 z
state S21 (3) tance
Wiring harness between S21 (2) – V11 Resis-
defective contact in connector) (female) (1) tance
Wiring harness between CP03 (female) (21), Resis-
Max. 1 z
(32), (33) – J05 – chassis ground tance
Wiring harness between S21 (2) – V11 Resis-
Max. 1 z
(female) (2) tance
4
Min. 1 Mz
S21 – V11 (female) (1) and chassis ground tance
Between (16) – (21), (32), (33) 7 – 14 z
42 PC400, 450-7E0
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
PC400, 450-7E0 43
Failure code [DXA0KB] PC-EPC Sol. Short Circuit 1

Action code Failure code PC-EPC Sol. Short Circuit
Trouble
E02 DXA0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to PC-EPC solenoid circuit.
trouble
Action of • Turns output to PC-EPC solenoid circuit OFF.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Output to PC-EPC solenoid can be checked with monitoring function.
(Code 01300: PC-EPC Sol. Curr.)
Related • If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
information 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.

Defective PC-EPC solenoid
and standard
value in normal Hot short (short circuit with Wiring harness between CP03 (female) (16) –
2 Voltage Max. 1 V
state 24V circuit) in wiring harness S21 (3) and chassis ground
Wiring harness between S21 (2) – V11
Voltage Max. 1 V
(female) (1) and chassis ground
3 Defective pump controller CP03 (female) Resistance
Between (16) – (21), (32), (33) 7 – 14 z
44 PC400, 450-7E0
PC400, 450-7E0 45
Failure code [DXE0KA] LS-EPC Sol. Open Circuit 1

Action code Failure code LS-EPC Sol. Open Circuit
Trouble
— DXE0KA (Pump controller system)
Contents of
• No current flows at output to LS-EPC solenoid circuit.
trouble
Problem that
• Travel speed Mi or Lo is high.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC Sol. Curr.)

Defective LS-EPC solenoid shooting without turning starting switch ON.
1
Between (1) – (2) 7 – 14 z
Disconnection in wiring harness A04 – V19 (female) (1) Max. 1 z
tance
Possible causes 2 (Disconnection in wiring or
and standard defective contact in connector) Wiring harness between CP03 (female) (21), Resis-
Max. 1 z
(32), (33) – J05 – chassis ground tance
value in normal
state Wiring harness between S21 (6) – V19 Resis-
Max. 1 z
(female) (2) tance
3
Min. 1 Mz
Between (6) – (21), (32), (33) 7 – 14 z
46 PC400, 450-7E0
PC400, 450-7E0 47
Failure code [DXE0KB] LS-EPC Sol. Short Circuit 1

Action code Failure code LS-EPC Sol. Short Circuit
Trouble
— DXE0KB (Pump controller system)
Contents of
• Abnormal current flowed at output to LS-EPC solenoid circuit.
trouble
Action of • Turns output to LS-EPC solenoid circuit OFF.
Problem that
• Travel speed Mi or Lo is high.
appears on
• Work equipment speed and swing speed are high in lifting mode (L).
machine
Related • Output to LS-EPC solenoid (current value) can be checked with monitoring function.
information (Code 01500: LS-EPC Sol. Curr.)

Defective LS-EPC solenoid
Possible causes
and standard
2
Voltage Max. 1 V
Between (6) – (21), (32), (33) 7 – 14 z
48 PC400, 450-7E0
PC400, 450-7E0 49
Failure code [DXE4KA] Service Current EPC Open Circuit 1

Action code Failure code Service Current EPC Open Circuit
Trouble
— DXE4KA (Pump controller system)
Contents of
• No current flows at output to service current EPC solenoid circuit.
trouble
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
information
(Code 01700: Service Sol. Curr.)

Defective service current shooting without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) – (2) 7 – 14 z
defective contact in connector) V30 (female) (1) tance
and standard
value in normal Wiring harness between CP03 (female) (3), Resis-
Max. 1 z
state (13), (23) – V30 (female) (2) tance
3
Min. 1 Mz
V30 (female) (1) and chassis ground tance
Between (26) – (3), (13), (23) 7 – 14 z
Circuit diagram related to service current EPC solenoid of pump controller
50 PC400, 450-7E0
Failure code [DXE4KB] Service Current EPC Short Circuit 1

Action code Failure code Service Current EPC Short Circuit
Trouble
— DXE4KB (Pump controller system)
Contents of
• Abnormal current flowed at output to service current EPC solenoid circuit.
trouble
Action of • Turns output to service current EPC solenoid circuit OFF.
Problem that
appears on • Attachment does not move.
machine
• This code-related troubleshooting is done only when ATT is provided. (Confirm settings on the
Related machine monitor.)
information • Output to service current EPC solenoid (current value) can be checked with monitoring function.
(Code 01700: Service Sol. Curr.)

Defective service current
1 EPC solenoid (Internal short V30 (male) Resistance
circuit or ground fault) Between (1) – (2) 7 – 14 z
Possible causes
and standard
2
Voltage Max. 1 V
V30 (female) (1) and chassis ground
Between (26) – (3), (13), (23) 7 – 14 z
Circuit diagram related to service current EPC solenoid of pump controller
PC400, 450-7E0 51
Failure code [DY20KA] Wiper Working Abnormality 1

Action code Failure code Wiper Working Abnormality
Trouble
— DY20KA (Machine monitor system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of
machine • Turns working output to wiper motor OFF.
monitor
Problem that
appears on • Windshield wiper does not operate.
machine
Related • Input of W signal in wiper working area (ON/OFF) can be checked with monitoring function.
information (Code 04502 Monitor Input 3)

Defective wiper motor W04 (male) Wiper blade Resistance
1
(Internal disconnection) Upper operating limit Max. 1 z
Between (6) – (5) Other than upper
Min. 1 Mz
operating limit
and standard Disconnection in wiring harness
value in normal Wiring harness between P01 (female) (5) – Resis-
defective contact in connector) W04 (female) (6)
state tance
Wiring harness between W04 (female) (5) – Resis-
Max. 1 z
P01 Wiper blade Voltage
Upper operating limit Max. 1 V
Between (5) –
chassis ground Other than upper
20 – 30 V
operating limit
52 PC400, 450-7E0
Circuit diagram related to wiper motor of machine monitor
PC400, 450-7E0 53
Failure code [DY20MA] Wiper Parking Abnormality 1

Action code Failure code Wiper Resting Abnormality
Trouble
— DY20MA (Machine monitor system)
Contents of
• When resting windshield wiper, P signal for storage area is not input.
trouble
Action of
machine • Cuts off output for resting to wiper motor OFF.
monitor
Problem that
appears on • Windshield wiper does not rest.
machine
Related • Input of P signal for wiper rest area (ON/OFF) can be checked with monitoring function.
information (Code 04502 Monitor Input 3)

Defective wiper motor W04 (male) Wiper blade Resistance
1
Storage area Max. 1 z
Between (4) – (5)
Working area Min. 1 Mz
and standard Disconnection in wiring harness
value in normal Wiring harness between P01 (female) (12) – Resis-
defective contact in connector) W04 (female) (4)
state tance
Wiring harness between W04 (female) (5) – Resis-
Max. 1 z
3 Defective machine monitor P01 Wiper blade Voltage
Between (12) – Storage area Max. 1 V
chassis ground Working area 20 – 30 V
54 PC400, 450-7E0
PC400, 450-7E0 55
Failure code [DY2CKB] Washer Drive Short Circuit 1

Action code Failure code Washer Drive Short Circuit
Trouble
— DY2CKB (Machine monitor system)
Contents of • When washer drive circuit was connected to GND (when output was turned ON), abnormal current
trouble flowed.
Action of
machine • Turns output to washer motor circuit OFF.
monitor
Problem that
appears on • Window washer operation stops.
machine
Related
information

Defective washer motor shooting without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Between (1) – (2) 5 – 20 z
and standard Hot short (Short circuit with
2
value in normal 24V circuit) in wiring harness Wiring harnesses between P01 (female) (3) –
state J04 – M06 (female) (2), – D02 (female) (8) Voltage Max. 1 V
and chassis ground
3 Defective machine monitor P01 Washer switch Voltage
Between (3) – OFF 20 – 30 V
chassis ground ON Max. 1 V
56 PC400, 450-7E0
Circuit diagram related to window washer motor of machine monitor
PC400, 450-7E0 57
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 1

Action code Failure code Wiper Drive (Fwd) Short Circuit
Trouble
— DY2DKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive (for) circuit.
trouble
Action of
machine • Turns output to wiper motor drive (for) circuit OFF.
monitor
Problem that
appears on • Wiper operation stops.
machine
Related
information

Defective wiper motor
1 (Internal short circuit or W04 (male) Continuity/Resistance
ground fault) Between (3) – (1) There is continuity
and standard Ground fault in wiring harness shooting without turning starting switch ON.
2
value in normal (Short circuit with GND circuit) Wiring harness between P01 (female) (9) – Resis-
state Min. 1 Mz
W04 (female) (3) and chassis ground tance
P01 Wiper switch Voltage
OFF Max. 3 V
Between (9) –
chassis ground Max. 3 V 20 – 30 V
ON
(Constant cycle)
58 PC400, 450-7E0
PC400, 450-7E0 59
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 1

Action code Failure code Wiper Drive (Rev) Short Circuit
Trouble
— DY2EKB (Machine monitor system)
Contents of
• Abnormal current flowed at output to wiper motor drive (rev.) circuit.
trouble
Action of
machine • Turns output to wiper motor drive (rev.) circuit OFF.
monitor
Problem that
appears on • Wiper operation stops.
machine
Related
information

1 (Internal short circuit or W04 (male) Continuity/Resistance
ground fault) Between (1) – (3) There is continuity
and standard Ground fault in wiring harness shooting without turning starting switch ON.
2
value in normal (Short circuit with GND circuit) Wiring harness between P01 (female) (10) – Resis-
state Min. 1 Mz
W04 (female) (1) and chassis ground tance
OFF Max. 3 V
Between (10) –
chassis ground Max. 3 V 20 – 30 V
ON
(Constant cycle)
60 PC400, 450-7E0
PC400, 450-7E0 61
SEN03603-01

© 2008 KOMATSU
All Rights Reserved
62
SEN03604-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
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 1
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 Windshield 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 IN” normally........................................................................... 42
E-21 Monitoring function fails to display “arm OUT” normally....................................................................... 44
E-22 Monitoring function fails to display “bucket CURL” normally ................................................................ 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
2 PC400, 450-7E0
PC400, 450-7E0 3
Before carrying out troubleshooting of electrical system 1

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 fus-
ible links to see if the power is supplied normally.
Types of
Fusible link Fuse No. Fuse capacity Destination of power
power supply
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
Switch power F04 3 20A Machine monitor
supply (65A) Wiper drive
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Electrical intake air heater relay
7 10A Rotary lamp (If equipped)
Switch power F04 8 10A Relay for lamp
supply (65A) Radio, Speaker
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
Switch power F04
13 20A Lamp, lamp relay drive
supply (65A)
14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant F05 Starting switch
17 10A
power supply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power Starting
20 5A Engine controller (ACC signal)
supply switch ACC
4 PC400, 450-7E0
Locations of fusible links and fuse No.
PC400, 450-7E0 5
Information contained in troubleshooting table 1

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 on the failure occurred as well as the troubleshooting
information

<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
2 Wiring harness which is not connected to power source (24 V) cir-
cuit is in contact with power source (24 V) circuit.
Possible causes
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence 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 troubleshoot-
ing, unless otherwise specified.
3 • If connector No. has no marks of “male” and “female”, discon-
nect 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
4 explained below for troubleshooting, unless otherwise 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.
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.
6 PC400, 450-7E0
E-1 Engine does not start 1

Trouble • Engine does not start (Engine does not turn).
• Engine starting circuit has following 2 start lock mechanisms:
Related 1) Start lock by the machine monitor password
information 2) Start lock by the safety lock lever
• In the case no error code for the engine controller mechanism is indicated

Battery voltage Specific gravity of battery
1 Low charge level 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.
Defective starting switch
3 H06 (male) Position Resistance
OFF Min. 1 Mz
Between (1) – (4)
START Max. 1 z
Defective work equipment
4 lock switch (internal short cir- S14 (female) Lock lever Resistance
cuit) Free Min. 1 Mz
Between (1) – (3)
Lock Max. 1 z
Possible causes
and standard shooting without turning starting switch ON.
Defective starting motor cut-
value in normal out relay R06 or R07 (inter- R06 (male), R07 (male) Resistance
state 5
nal disconnection or short Between (1) – (2) 100 – 500 z
circuit)
Between (3) – (5) Min. 1 Mz
(If power supply and starting input and output are normal
but starting motor does not turn, starting motor is defective.)
Defective starting motor
Starting
6 (Internal disconnection or Starting motor Voltage
switch
breakage)
Power supply: Between terminal
20 – 30 V
B – chassis ground
START
Starting input: Between terminal C –
20 – 30 V
chassis ground and chassis ground
Defective alternator
7 Alternator Voltage
(Internal short circuit)
Between terminal R –
Max. 1 V
chassis ground
PC400, 450-7E0 7

Wiring harness between F01-17 outlet – H06 Resis-
Max. 1 z
(female) (1) tance
Wiring harness between H06 (female) (4) – Resis-
Max. 1 z
J01 – R06 (female) (5) tance
M17 (female) (1) tance
defective contact in connector) Wiring harness between F01-3 outlet – S14 Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
Max. 1 z
Max. 1 z
J04 – chassis ground tance
Possible causes
and standard
value in normal Wiring harness between battery relay termi-
Resis-
state nal B (R04) – F05 – F01-17D inlet and chas- Min. 1 Mz
tance
sis ground
Wiring harness between F01-17 outlet – H06 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Ground fault in wiring harness J01 – R06 (female) (5) and chassis ground Min. 1 Mz
9 tance
(Short circuit with GND circuit)
Min. 1 Mz
M17 (female) (1) and chassis ground tance
Wiring harness between F01-3 – S14 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Wiring harness between S14 (female) (3) – Resis-
Min. 1 Mz
R06 (female) (1) and chassis ground tance
Min. 1 Mz
J05 – P02 (female) (14) and chassis ground tance
Hot short (Short circuit with
10
24V circuit) in wiring harness Wiring harness between P02 (female) (11) –
J02 – M17 (female) (2), – D01 (female) (6), – Voltage Max. 1 V
alternator terminal R and chassis ground
8 PC400, 450-7E0
Circuit diagram related to engine start and battery charging
PC400, 450-7E0 9
E-2 Auto-decelerator does not operate 1

Trouble • 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
Related
when operating the auto-decelerator.
information
• Check all the monitoring indications after starting the engine.

In the case monitoring is not normally indicated, proceed to trouble-
shooting No. E-18.
Monitoring code Item Normal display
1 Defective boom RAISE signal
Operation of lever:
01900 Boom RAISE ON
Lever in neutral: OFF
shooting No. E-19.
2 Defective boom LOWER signal
Operation of lever:
01900 Boom LOWER ON
shooting No. E-20.
3 Defective arm IN signal
Operation of lever:
Possible causes
01900 Arm IN ON
and standard
value in normal
state In the case monitoring is not normally indicated, proceed to trouble-
shooting No. E-21.
4 Defective arm OUT signal
Operation of lever:
01900 Arm OUT ON
shooting No. E-22.
Defective bucket CURL sig- Monitoring code Item Normal display
5
nal Operation of lever:
01901 Bucket CURL ON
shooting No. E-23.
Defective bucket DUMP sig- Monitoring code Item Normal display
6
nal Operation of lever:
01901 Bucket DUMP ON
10 PC400, 450-7E0

shooting No. E-24.
7 Defective swing signal
Operation of lever:
01900 Swing ON
shooting No. E-25.
Possible causes Monitoring code Item Normal display
8 Defective travel signal
and standard Operation of lever:
value in normal 01900 Travel ON
state Lever in neutral: OFF
shooting No. E-27.
9 Defective attachment signal
Operation of lever:
01901 Service ON
Since trouble is in system, troubleshooting cannot be carried out. (If
10 Defective pump controller causes 1 – 9 above are not detected, engine controller may be
defective.)
PC400, 450-7E0 11
E-3 Automatic warming-up does not operate 1

Trouble • Automatic warming-up system does not operate
• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to
Related 1,250 rpm.
information • 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.

shooting No. E-11.
Possible causes Defective engine coolant Monitoring code Item Normal display
1
and standard temperature signal Compare with actual
value in normal Engine coolant
04102 engine coolant
state temperature
temperature
Since trouble is in system, troubleshooting cannot be carried out.
2 Defective pump controller (If causes stated above are not detected, engine controller may be
defective.)
12 PC400, 450-7E0
PC400, 450-7E0 13
E-4 Preheater does not operate 1

Trouble (1) • When starting switch is turned to HEAT position, preheating monitor does not light up.
Related • Input of preheating signal (ON/OFF) can be checked with monitoring function.
information (Code 04500: Monitor Input 1)

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 2 (Disconnection in wiring or
Max. 1 z
value in normal J02 (male) (7) tance
state
a Prepare with starting switch OFF
P02 Starting switch Voltage
Between (18) – OFF Max. 1 V
chassis ground HEAT 20 – 30 V
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related • During low temperature (coolant temperature below 30°C), pump controller drives the heater relay
information for 100 sec. after engine start to automatically preheat.

a Prepare with starting switch OFF
Defective starting switch H06 (male) Starting switch Resistance
1
(Internal disconnection) OFF Min. 1 Mz
Between (1) – (3)
HEAT Max. 1 z
Defective heater relay Heater relay Resistance
2
Possible causes (Internal disconnection)
and standard Coil terminal – chassis ground
value in normal Between contact terminals Min. 1 Mz
state
Defective intake air heater shooting without turning starting switch ON.
3
(Internal disconnection).
Between heater terminals Normal if conductive
4 (Disconnection in wiring or Wiring harness between H06 (female) (3) – Resis-
Max. 1 z
J02 – Heater relay terminal R17 tance
Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M (R03) – Heater relay terminal R15 tance
14 PC400, 450-7E0
Circuit diagram related to engine preheater
PC400, 450-7E0 15
E-5 All work equipment, swing, and travel mechanism do not move 1
Trouble • All travel, swing, and work equipment mechanism do not move.
Related
—
information

1 Defective fuse No. 3 If fuse is burnt out, the circuit probably has ground fault.
Defective safety lock switch
2 S14 (female) Lock lever Resistance
(internal disconnection)
Lock Min. 1 Mz
Between (1) – (2)
Free Max. 1 z
Defective PPC lock solenoid
3 (Internal disconnection or V01 (male) Resistance
short circuit) Between (1) – (2) 20 – 60 z
Possible causes
4 diode D01
and standard D01 (male) Resistance
value in normal
Between (8) – (4) Min. 1 Mz
state
Wiring harness between F01-3 outlet – J06 – Resis-
defective contact in connector) Wiring harness between S14 (male) (2) – Resis-
Max. 1 z
J02 – V01 (male) (2) tance
Max. 1 z
Ground fault in wiring harness Min. 1 Mz
6 S14 (male) (1) and chassis ground tance
(Short circuit with GND circuit)
Wiring harness between S14 (male) (2) –
Resis-
J02 – V01(female) (2), – D01(female) (8) Min. 1 Mz
tance
and chassis ground
16 PC400, 450-7E0
Circuit diagram related to PPC lock solenoid
PC400, 450-7E0 17
E-6 Power maximizing function does not operate 1

Trouble • Power maximizing function does not work.
• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed
Related during work equipment operation while the engine is running in A- or E-mode.
information • Input state of power maximizing switch (left knob switch) can be checked with monitoring function
(Code 02200: Switch Input 1)

Defective power maximizing
2 switch (Internal disconnec- S11(male) Switch Resistance
tion) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
3 (Disconnection in wiring or Wiring harness between F01-9 outlet – S11 Resis-
Max. 1 z
Possible causes (female) (1) tance
and standard Wiring harness between S11 (female) (2) – Resis-
value in normal Max. 1 z
CP01 (female) (11) tance
state
Ground fault in wiring harness Wiring harness between F01-9 outlet – S11 Resis-
4 Min. 1 Mz
(Short circuit with GND circuit) (female) (1) and chassis ground tance
Wiring harness between S11 (female) (2) – Resis-
Min. 1 Mz
CP01 (female) (11) and chassis ground tance
5 Defective pump controller CP01 Switch Voltage
Between (11) – Released Max. 1 V
chassis ground Pressed 20 – 30 V
Circuit diagram related to power max. switch
18 PC400, 450-7E0
PC400, 450-7E0 19
E-7 Machine monitor does not display at all 1

Trouble • Machine monitor does not display at all when starting switch is turned ON
Related
—
information

2 (Disconnection in wiring or Wiring harness between P01(female) (1), (2) – Resis-
Max. 1 z
defective contact in connector) J06 – F01-3 outlet tance
Wiring harness between P01 (female) (6), Resis-
Max. 1 z
(7) – chassis ground tance
Possible causes
and standard
value in normal Ground fault in wiring harness shooting without turning starting switch ON.
3
state (Short circuit with GND circuit) Wiring harness between P01(female) (1), (2) – Resis-
Min. 1 Mz
J06 – F01-3 outlet and chassis ground tance
P01 (female) Voltage/Resistance
4 Defective machine monitor Between (1), (2) –
Voltage: 20 – 30 V
chassis ground
Between (6), (7) –
Resistance: Max. 1 z
chassis ground
20 PC400, 450-7E0
Circuit diagram related to power source in monitor panel
PC400, 450-7E0 21
E-8 Machine monitor does not display some items 1

Trouble • Machine monitor does not display some items when starting switch is turned ON
Related
—
information

When following switches are operated, if all LCD panel is lighted up
Possible causes Defective machine monitor
1 (all surface becomes white), LCD panel is normal.
and standard LCD
• Switch operation: [ ] + [A] (Simultaneous operation)
value in normal
state Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective machine monitor causes stated above are not detected, engine controller may be
defective.)
E-9 Contents of display by machine monitor are different from

applicable machine 1
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
—
information

In the case monitoring display is not normal, proceed to failure code
code [DA2SKQ].
Possible causes Defective model code signal Monitoring code Item Normal display
1
and standard (Internal defect) 00200 Controller model
value in normal code 300
state 00201 Select model
Since trouble is in system, troubleshooting cannot be carried out.
2 Defective machine monitor (If causes stated above are not detected, engine controller may be
defective.)
22 PC400, 450-7E0
E-10 Fuel level monitor was lighted in red while engine running 1
Trouble • 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.
Related
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
information
(Code 04200: Fuel Level Sensor Vol.)

Low fuel level
1 a Add fuel
(When system is normal)
Defective fuel level sensor P21 (male) Fuel level Resistance
2
Between (1) – FULL (Upper limit) Approx. 12 z
Possible causes chassis ground EMPTY (Lower limit) 85 – 110 z
and standard
state 3 (Disconnection in wiring or
Max. 1 z
4 Defective machine monitor P02 (female) Fuel level Resistance
chassis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
PC400, 450-7E0 23
E-11 Engine coolant temperature gauge does not indicate normally 1

• While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble 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.
Related
(Code 04105: Engine coolant temperature)
information
• Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated
(if yes, diagnose that failure first.)

Engine coolant tem-
TWTR (male) Resistance
perature
Defective engine coolant 0°C 30 – 37 kz
temperature sensor 25°C 9.3 – 10.7 kz
1
short circuit) Between (B) – (A) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (B) –
All range Min. 1 Mz
chassis ground
TWTR (female) (A) tance
Possible causes
Wiring harness between TWTR (female) (A) – Resis-
value in normal
3
Min. 1 Mz
TWTR (female) (A) and chassis ground tance
Hot short (Short circuit with switch ON and carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between CE01 (female) (15) –
Voltage Max. 1 V
TWTR (female) (A) and chassis ground
Engine coolant tem-
perature
5 Defective engine controller 0°C 30 – 37 kz

25°C 9.3 – 10.7 kz
Between (15) –
50°C 3.2 – 3.8 kz
chassis ground
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
24 PC400, 450-7E0
Circuit diagram related to engine coolant temperature sensor
PC400, 450-7E0 25
E-12 Hydraulic oil temperature gauge does not indicate normally 1

• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range (C).
Trouble
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring function.
information (Code 04402: Hydraulic oil temperature)

Defective hydraulic oil tem-
Engine coolant tem-
perature sensor P22 (male) Resistance
1 perature
short circuit) Between (1) – (2) 90 – 3.5 kz
Between (2) – 10 – 100°C
Min. 1 Mz
chassis ground
and standard
state Ground fault in wiring harness shooting without turning starting switch ON.
3
Min. 1 Mz
4
Voltage Max. 1 V
Engine coolant tem-
P02 Resistance
5 Defective machine monitor perature
Between (12) – (13) 90 – 3.5 kz
Between (12) – 10 – 100°C
Min. 1 Mz
chassis ground
Circuit diagram related to hydraulic oil temperature sensor
26 PC400, 450-7E0
E-13 Fuel level gauge does not operate normally 1

• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F)
Related • Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
information (Code 04200: Fuel level sensor voltage)

Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) FULL (Upper limit) Approx. 12 z
Between (1) –
Max. 1 z
Possible causes
and standard
value in normal Ground fault in wiring harness shooting without turning starting switch ON.
3
state (Short circuit with GND circuit) Wiring harness between P02 (female) (2) – Resis-
Min. 1 Mz
4
Voltage Max. 1 V
5 Defective machine monitor P02 Fuel level Resistance
Circuit diagram related to fuel level sensor
PC400, 450-7E0 27
E-14 Swing lock monitor does not indicate normally 1

• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned ON, swing lock monitor lights up.
Related • Input from swing lock switch (ON/OFF) can be checked with monitoring function.

Defective swing lock switch
1 (Internal disconnection or S04 (female) Swing lock switch Resistance
short circuit) OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
2 (Disconnection in wiring or Wiring harness between P02 (female) (17) – Resis-
Max. 1 z
defective contact in connector) J02 – S04 (male) (1) tance
Wiring harness between S04 (male) (2) – Resis-
and standard
3
Min. 1 Mz
J02 – S04 (male) (1) and chassis ground tance
4
Voltage Max. 1 V
J02 – S04 (male) (1) and chassis ground
5 Defective machine monitor P02 Swing lock switch Voltage
Between (17) – OFF 20 – 30 V
28 PC400, 450-7E0
Circuit diagram related to swing lock switch
PC400, 450-7E0 29
E-15 When monitor switch is operated, monitor displays nothing 1

Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related
—
information

and standard
value in normal 1 Defective machine monitor Since trouble is in system, troubleshooting cannot be carried out.
state
Trouble (2) • When auto-decelerator switch is operated, auto-decelerator monitor is not displayed.
Related
a If auto-decelerator fails to operate, proceed with troubleshooting No. E-2.
information

and standard
state
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related
a If travel speed selection fails, proceed with troubleshooting No. H-22.
information

and standard
state
Trouble (4) • When wiper switch is operated, wiper monitor is not displayed.
Related
a If wiper fails to operate, proceed with troubleshooting No. E-16.
information

and standard
state
• When select switch is operated, adjust screen is not displayed.

Trouble (5) • 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

and standard
state
30 PC400, 450-7E0
PC400, 450-7E0 31
E-16 Windshield wiper does not operate 1

Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
Related • Input from window limit switch (ON/OFF) can be checked with monitoring function.

Defective window rear limit
W03 (male) Front window Resistance
switch
1 When installed to
(Internal disconnection or Min. 1 Mz
short circuit) front
Between (1) – (2)
When retracted to
Max. 1 z
rear
W04 (male) Resistance
2 (Internal disconnection or
short circuit) Between (3) – (1)
Between (3), (1) –
Min. 1 Mz
chassis ground
3 (Disconnection in wiring or Wiring harness between P01 (female) (9) – Resis-
Max. 1 z
Possible causes W04 (male) (3) tance
and standard Wiring harness between P01 (female) (10) – Resis-
value in normal Max. 1 z
W04 (male) (1) tance
state
4
Min. 1 Mz
W03 (male) (2) and chassis ground tance
P02 Front window Voltage
Defective machine monitor
(Window limiter switch system) When installed to
20 – 30 V
Between (15) – front
chassis ground When retracted to
Max. 1 V
rear
5
Defective machine monitor
(Wiper motor system) Between (9) – OFF Max. 3 V
chassis ground
Between (10) – ON Max. 3 V 20 – 30 V
chassis ground (Constant cycle)
32 PC400, 450-7E0
Circuit diagram related to windshield wiper motor
PC400, 450-7E0 33
Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related
information

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault (See cause 4).
Defective washer motor
2 (Internal disconnection or M06 (male) Resistance
short circuit) Between (1) – (2) 5 – 20 z
3 (Disconnection in wiring or Wiring harness between F01-4 – J03 – J06 – Resis-
Max. 1 z
M06 (female) (1) tance
Wiring harness between M06 (female) (2) – Resis-
J04 – P01 (female) (3) tance
and standard
Wiring harness between F01-4 – J03 – J06 –
M06 (female) (1), – D02 (female) (4), – other Resis-
Ground fault in wiring harness Min. 1 Mz
4
(Short circuit with GND circuit) harnesses between related circuits and tance
chassis ground
Wiring harness between M06 (female) (2) –
Resis-
J04 – P01 (female) (3), – D02 (female) (8) Min. 1 Mz
tance
and chassis ground
Defective machine monitor Window washer
5 P01 Voltage
(Window limiter switch system) switch
Between (3) – OFF 20 – 30 V
34 PC400, 450-7E0
Circuit diagram related to window washer motor of machine monitor
PC400, 450-7E0 35
E-17 Machine push-up function does not operate normally 1

• Machine push-up function does not oper-
Trouble (1) Machine push-up function does not operate.
ate normally
Related
• When machine push-up function is set to high pressure, solenoid is de-energized.
information

1 Defective fuse No.2 If fuse is broken, circuit probably has ground fault. (See Cause 6)
Defective machine push-up Machine push-up
2 S05 (female) Resistance
switch (Internal disconnection) switch
Low pressure set Max. 1 z
Between (1) – (2)
High pressure set Min. 1 Mz
Defective machine push-up shooting without turning starting switch ON.
solenoid
3 V06 (male) Resistance
short circuit or ground fault) Between (1) – (2) 20 – 60 z
Possible causes
4 diode D02
and standard D02 (male) Resistance (Continuity)
value in normal
Between (3) – (7) Min. 1 Mz (without continuity)
state
Wiring harness between F01-2 outlet – S05 Resis-
Disconnection in wiring harness (male) (1) Max. 1 z
tance
defective contact in connector) Wiring harness between S05 (male) (2) – Resis-
Max. 1 z
J07 – V06 (female) (2) tance
Max. 1 z
Wiring harness between F01-2 outlet – S05
Ground fault in wiring harness (male) (1), – other harnesses between Resis-
Min. 1 Mz
6 tance
(Short circuit with GND circuit) related circuits and chassis ground
Wiring harness between S05 (male) (2) –
Resis-
J07 – V06 (female) (2), – D02 (female) (3) Min. 1 Mz
tance
and chassis ground
36 PC400, 450-7E0
• Machine push-up function does not oper-

Trouble (2) Machine push-up function does not release.
ate normally
Related
• When machine push-up function is set to low pressure, solenoid is energized.
information

Defective machine push-up Machine push-up
1 S05 (female) Resistance
Possible causes switch (Internal short circuit) switch
and standard Low-pressure set Max. 1 z
value in normal Between (1) – (2)
High-pressure set Min. 1 Mz
state
2
24V circuit) in wiring harness Wiring harness between S05 (female) (2) –
J07 – V06 (female) (2), – D02 (female) (3) Voltage Max. 1 V
and chassis ground
Circuit diagram related to machine push-up solenoid
PC400, 450-7E0 37
E-18 Monitoring function fails to display “boom RAISE” normally 1

Trouble • Boom Raise operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Pressure Switch 1)
information

Defective boom RAISE PPC
1 oil pressure switch (Internal P06 (male) Boom lever Resistance
disconnection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom RAISE Max. 1 z
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Boom lever Voltage
Between (10) – Neutral 20 – 30 V
chassis ground Boom RAISE Max. 1 V
38 PC400, 450-7E0
Circuit diagram related to boom RAISE PPC oil pressure switch
PC400, 450-7E0 39
E-19 Monitoring function fails to display “boom LOWER” normally 1

Trouble • Boom LOWER operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Defective boom LOWER carry out troubleshooting.
PPC oil pressure switch
1 P02 (male) Boom lever Resistance
short circuit) Neutral Min. 1 Mz
Between (1) – (2)
LOWER Max. 1 z
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Boom lever Voltage
chassis ground LOWER Max. 1 V
40 PC400, 450-7E0
Circuit diagram related to boom LOWER PPC oil pressure switch
PC400, 450-7E0 41
E-20 Monitoring function fails to display “arm IN” normally 1

Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective arm IN pressure carry out troubleshooting.
sensor
1 P04 Voltage
short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
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
PC400, 450-7E0 43
E-21 Monitoring function fails to display “arm OUT” normally 1

Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective arm OUT PPC oil
1 pressure switch (Internal dis- P08 (male) Arm lever Resistance
connection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
OUT Max. 1 z
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Arm lever Voltage
chassis ground OUT Max. 1 V
44 PC400, 450-7E0
Circuit diagram related to arm OUT PPC oil pressure switch
PC400, 450-7E0 45
E-22 Monitoring function fails to display “bucket CURL” normally 1

Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective bucket CURL pres-
1 sure sensor (internal discon- P01 (male) Bucket lever Voltage
nection or short circuit) Between (3) – (1) Neutral 4.5 – 5.5 V
Between (2) – (1) CURL 0.5 – 5.5 V
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
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
PC400, 450-7E0 47
E-23 Monitoring function fails to display “bucket DUMP” normally 1

Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective bucket DUMP PPC
1 oil pressure switch (Internal P05 (male) Bucket lever Resistance
disconnection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Dump Max. 1 z
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Bucket lever Voltage
chassis ground Dump Max. 1 V
48 PC400, 450-7E0
Circuit diagram related to bucket DUMP PPC oil pressure witch
PC400, 450-7E0 49
E-24 Monitoring function fails to display “swing” normally 1

Trouble • Swing is not displayed normally by machine monitoring function (Special function)
Related
information

Defective swing left PPC oil
1 pressure switch (Internal dis- P07 (male) Swing lever Resistance
Between (1) – (2)
Left Max. 1 z
Defective swing right PPC oil
2 pressure switch (Internal dis- P03 (male) Swing lever Resistance
Between (1) – (2)
Right Max. 1 z
Disconnection in wiring harness P03 (female) (2), – P07 (female) (2) Max. 1 z
tance
Max. 1 z
and standard chassis ground tance
value in normal
Max. 1 z
4
P03 (female) (2), – P07 (female) (2) and Min. 1 Mz
tance
chassis ground
5
P03 (female) (2), – P07 (female) (2) and Voltage Max. 1 V
chassis ground
6 Defective pump controller CP03 Bucket lever Voltage
chassis ground Left or Right Max. 1 V
50 PC400, 450-7E0
Circuit diagram related to right and left swing PPC oil pressure witches
PC400, 450-7E0 51
E-25 Monitoring function fails to display “travel” normally 1

Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective travel PPC pres- carry out troubleshooting.
sure switch
1 P09 (male) Travel lever Resistance
Between (1) – (2)
Front or rear Max. 1 z
defective contact in connector) J01 – P09 (female) (2) tance
Max. 1 z
Possible causes
state 3
J01 – P09 (female) (2), – M14 (female) (2) Min. 1 Mz
tance
and chassis ground
4
J01 – P09 (female) (2), – M14 (female) (2) Voltage Max. 1 V
and chassis ground
chassis ground Front or rear Max. 1 V
52 PC400, 450-7E0
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-7E0 53
E-26 Monitoring function fails to display “travel differential pressure”

normally 1
• Travel differential pressure is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left
Related
travel PPC circuits (during steering).
information

Defective travel steering carry out troubleshooting.
PPC oil pressure switch
1 P10 (male) Travel lever Resistance
Between (1) – (2)
Left or Right only Max. 1 z
and standard
3
Min. 1 Mz
4
Voltage Max. 1 V
chassis ground Left or Right only Max. 1 V
54 PC400, 450-7E0
Circuit diagram related to travel steering PPC oil pressure switch
PC400, 450-7E0 55
E-27 Monitoring function fails to display “service” normally 1

Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related
information

Defective (front) PPC oil
1 pressure switch (Internal dis- S10 (male) Service pedal Resistance
Between (1) – (2)
Front Max. 1 z
Defective (rear) PPC oil
2 pressure switch (Internal dis- S11(male) Service pedal Resistance
Between (1) – (2)
Rear Max. 1 z
Disconnection in wiring harness S10 (female) (2), – S11 (female) (2) Max. 1 z
tance
defective contact in connector) Wiring harness between S10 (female) (1) – Resis-
Max. 1 z
and standard chassis ground tance
value in normal
state Wiring harness between S11 (female) (1) – Resis-
Max. 1 z
4
S10 (female) (2), – S11 (female) (2) and chas- Min. 1 Mz
tance
sis ground
5
S10 (female) (2), – S11 (female) (2) and chas- Voltage Max. 1 V
sis ground
6 Defective pump controller CP02 Service pedal Voltage
chassis ground Front or rear Max. 1 V
56 PC400, 450-7E0
Circuit diagram related to service PPC oil pressure switch
PC400, 450-7E0 57
E-28 The KOMTRAX system does not operate normally 1

Trouble • The KOMTRAX system does not operate normally
• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply L80 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37) and (38) ply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (6) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Between (36) and
Starting switch ACC 20 – 30 V
(37), (38)
Between (28) – (37),
Alternator R 20 – 30 V
(38)
Possible causes and carry out troubleshooting.
and standard Defective starting switch C
value in normal 3 L80 Signal Voltage
signal
state Between (27) and
Starting switch C 20 – 30 V
(37), (38)
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4 a Prepare with starting switch OFF, then carry out troubleshooting
state
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
5 Number of unsent mails LED (7) Normal state
7 segments 0–9
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
58 PC400, 450-7E0
Indicator lamps of KOMTRAX terminal L80 connector
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning 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)
PC400, 450-7E0 59
E-29 Air conditioner does not operate 1

Trouble • Air conditioner does not start.
Related • For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance
information standard, “Air conditioner system.”

1 Defective fuse No. 11 If fuse is burnt, circuit probably has ground fault.
Defective A/C Hi/Lo pressure a Prepare with starting switch OFF, then carry out trouble-
switch shooting without turning starting switch ON.
2
(Internal disconnection or P17 (Male) Resistance
defective contact)
Wiring harness between F01-11 outlet – M26 Resis-
Max. 1 z
(male) (5) tance
Wiring harness between M26 (male) (12) – Resis-
Possible causes defective contact in connector) P17 (female) (1) tance
and standard Wiring harness between M26 (male) (8) – Resis-

Max. 1 z
value in normal chassis ground tance
Max. 1 z
J04 – A07 – chassis ground tance
Ground fault in wiring harness Wiring harness between F01-11 outlet – M26 Resis-
4 Min. 1 Mz
(Short circuit with GND circuit) (male) (5) and chassis ground tance
Wiring harness between M26 (male) (12) – Resis-
Min. 1 Mz
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (5) – (8) 20 – 30 V
60 PC400, 450-7E0
Circuit diagram related to air conditioner
PC400, 450-7E0 61
E-30 Travel alarm does not sound or does not stop sounding 1
• Alarm does not sound during travel.
Trouble
• Alarm sounds in stopped state.
Related
—
information

shooting No. E-25.
2 Defective travel signal Operation of lever:

01900 Travel ON
When the monitoring display is not correct, proceed to diagnosis for
“Travel is not normally indicated' in the monitoring function”
carry out troubleshooting (insert T-adapter).
Defective travel alarm M14 Travel lever Voltage
Possible causes 3 (Internal disconnection or Neutral Max. 1 V
and standard short circuit) Between (1) – (2)
value in normal Operated 20 – 30 V
state If above voltage is normal and travel alarm does not sound, travel
alarm is defective.
A07 – M14 (female) (1) tance
Wiring harness between M14 (female) (2) – Resis-
Max. 1 z
J01 (19) tance
5
(Short circuit with GND circuit) Wiring harness between F01-15 outlet – J03 – Resis-
Min. 1 Mz
A07 – A14 (female) (1) and chassis ground tance
Since trouble is in system, troubleshooting cannot be carried out. (If
causes 1 – 5 above are not detected, travel alarm may be defective.)
62 PC400, 450-7E0
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-7E0 63
E-31 Horn does not sound 1

Trouble • Horn does not sound
Related
information

1 Defective fuse No. 5 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
Voltage 20 – 30 V
horn switch turned ON)
3 Defective high tone horn a Prepare with starting switch OFF, then carry out trouble-
Resis-
Between M07 (female) (1) – chassis ground Max. 1 z
tance
If above is normal, the horn is defective
Between M08 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
4 Defective low tone horn a Prepare with starting switch OFF, then carry out trouble-
Possible causes Resis-
Between M08 (female) (1) – chassis ground Max. 1 z
and standard tance
value in normal If above is normal, the horn is defective
state
Wiring harness between F01 (5) – S10 Resis-
Max. 1 z
(female) – R08 (female) (3) tance
5 (Disconnection in wiring or Wiring harness between S10 (female) (2) – Resis-
Max. 1 z
R08 (female) – A07 – M07 (female) (2) tance
Max. 1 z
A07 – M08 (female) (2) tance
Max. 1 z
J04 (20) – A07 – chassis ground tance
Wiring harness between F01 (5) – S10
Resis-
(female) – R08 (female) (3) and chassis Min. 1 Mz
tance
Ground fault in wiring harness ground
6
(Short circuit with GND circuit) Wiring harness between S10 (female) (2) –
Resis-
R08 (female) – A07 – M07 (female) (2) and Min. 1 Mz
tance
chassis ground
Min. 1 Mz
A07 – M08 (female) (2) and chassis ground tance
64 PC400, 450-7E0
Circuit diagram related to horn
PC400, 450-7E0 65
SEN03604-01

© 2009 KOMATSU
All Rights Reserved
66
SEN03605-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
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 1
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
2 PC400, 450-7E0
PC400, 450-7E0 3
System chart for hydraulic and mechanical system 1
4 PC400, 450-7E0
a 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 5
Information contained in troubleshooting table 1

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 on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting
Presumed 2
Cause for presumed failure
cause and [Contents]
(The attached No. is for fil-
standard value • The standard values in normalcy by which to judge “Good”
3 ing and reference purpose
in normalcy or “No Good” about presumed causes.
only. It does not stand for
• References for making judgement of “good” or “No Good”
any priority.)
4
6 PC400, 450-7E0
PC400, 450-7E0 7
H-1 All work equipment lack power, or travel and swing speeds are slow1
Trouble • Speed or power of all work equipment, travel, and swing is low
Related
• Set the working mode in P-mode before start.
information

a Prepare with engine stopped, then run engine at high
idle and carry out troubleshooting.
1 Malfunction of unload valve Control lever Unload pressure
4.12 ± 1.0 MPa
All levers in neutral
{42 ± 10 kg/cm2}
Control lever Main relief pressure
Defective adjustment or mal- 33.34 – 36.77 MPa
2 Arm IN
function of main relief valve {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.
Malfunction of self pressure
Possible causes 3 Control lever Control circuit basic pressure
reducing valve
and standard 2.84 – 3.43 MPa
value in normal All levers in neutral
{29 – 35 kg/cm2}
state
Measured oil Measurement condi-
Oil pressure ratio
pressure tion
Defective adjustment or mal- Pump discharge
4 1
function of PC valve pressure Swing lock switch: ON
PC valve output Arm IN relief Approx. 0.6
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
LS-EPC output
Travel speed Travel lever
5 Malfunction of LS-EPC valve pressure
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Hi Operated 0 MPa {0 kg/cm2}
8 PC400, 450-7E0

Oil pressure ratio
Measured oil Travel with no load
pressure All levers in neutral (Lever operated
Possible causes Defective adjustment or mal- halfway)
6
and standard function of LS valve Pump discharge
value in normal 1
pressure Almost same pres-
state sure
LS valve output Approx. 0.6
If oil pressure does not become normal after adjustment, LS valve
may have malfunction or internal defect. Check LS valve directly.
7 Malfunction of servo piston Servo piston may have malfunction. Check it directly.
If any cause above is detected, cause may be lowering of perfor-
8 Defective piston pump
mance, malfunction, or internal defect of piston pump.
PC400, 450-7E0 9
H-2 Engine speed sharply drops or engine stalls 1

Trouble • Engine speed lowers extremely or engine stalls.
Related
information

Control lever Main relief pressure
Defective adjustment or mal- 33.34 – 36.77 MPa
1 Arm IN
function of main relief valve {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 Measurement
Oil pressure ratio
pressure condition
Defective adjustment or mal- Pump discharge
2 1
function of PC valve pressure Swing lock switch: ON
Possible causes PC valve output Arm IN relief Approx. 0.6
and standard pressure (Approx. 3/5)
value in normal If oil pressure does not become normal after adjustment, PC valve
state may have malfunction or internal defect. Check PC valve directly.
Oil pressure ratio
Defective adjustment or mal- halfway)
3
function of LS valve Pump discharge
1
pressure Almost same
LS valve output pressure Approx. 0.6
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
4
servo devices them directly.
10 PC400, 450-7E0
H-3 No work equipment, swing or travel move 1

Trouble • All work equipment, swing, and travel mechanism do not move.
Related
information

Malfunction of PPC lock Work equipment lock lever Solenoid output pressure
1
solenoid valve Lock 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Free
{29 – 35 kg/cm2}
Possible causes a Prepare with engine stopped, then run engine at high
and standard idle and carry out troubleshooting.
value in normal Malfunction of self pressure
state 2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
• Piston pump may have malfunction or internal defect. Check it by
following method.
3 Defective piston pump
Crank the engine with oil pressure measurement plug removed.
If oil flows out, the piston pump is normal.
Pump shaft may not revolve because of defect in damper. Check
4 Defective damper
damper directly.
H-4 Abnormal noise is heard from around hydraulic pump 1

Failure
• An abnormal noise is heard from around hydraulic pump.
phenomenon
Relative
information
Cause Standard value in normalcy and references for troubleshooting

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.
Presumed It is presumed that the cap of hydraulic tank is clogged, thereby
cause and 3 Hydraulic tank cap clogged
causing negative pressure inside the tank. Make a visual check.
standard value
It is presumed that the strainer in the hydraulic tank is clogged,
in normalcy Hydraulic tank strainer
4 thereby causing negative pressure in the suction circuit. Make a
clogged
visual check.
The piston pump is suspected of an internal failure. Check the pump
5 Piston pump defective
itself.
PC400, 450-7E0 11
H-5 Auto-decelerator does not work 1

Trouble • Auto-decelerator does not operate.
• Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated.
Related (Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
information circuit.)

Possible causes idle and carry out troubleshooting.
and standard
Malfunction of travel PPC Travel lever PPC valve output pressure
value in normal 1
state valve (shuttle valve) Neutral 0 MPa {0 kg/cm2}
Min. 2.75 MPa
Operated
{Min. 28 kg/cm2}
H-6 Fine control mode does not function or responds slow 1

Trouble • Fine control performance or response is low.
Related
information

LS-EPC output
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
2 Clogging of LS circuit orifice Orifice of LS circuit may be clogged. Check it directly.
Possible causes a Prepare with engine stopped, then run engine at high
and standard idle and carry out troubleshooting.
value in normal
state Oil pressure ratio
Defective adjustment or mal- halfway)
3
function of LS valve Pump discharge
1
pressure Almost same pres-
LS valve output sure Approx. 0.6
12 PC400, 450-7E0
H-7 Boom moves slowly or lacks power 1

Trouble • Speed or power of boom is low
Related
information

R.H. work equipment control
Malfunction of right PPC PPC valve output pressure
1 lever
valve (boom circuit)
Neutral 0 MPa {0 kg/cm2}
In boom Raise operation Min. 2.75 MPa
In boom Lower operation {Min. 28 kg/cm2}
Malfunction of merge-divider Travel lever Solenoid output pressure
2
solenoid valve At neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
Malfunction of merge-divider Merge-divider valve (main/LS) of control valve may have malfunc-
3
valve (main/LS) tion. Check it directly.
Malfunction of boom control Spool of boom control valve (Lo/Hi) may have malfunction. Check it
4
valve (spool) directly.
Malfunction of boom control
Possible causes Pressure compensation valve of boom control valve (Lo/Hi) may
5 valve (pressure compensa-
and standard have malfunction. Check it directly.
tion valve)
value in normal
state Malfunction of boom control Regeneration valve of boom control valve (Lo) may have malfunc-
6
valve (regeneration valve) tion or defective seal. Check it directly.
Malfunction of boom control Lock valve of boom control valve (Lo) may have malfunction. Check
7
valve (lock valve) it directly.
Malfunction of boom control Check valve of boom control valve (Hi) may have malfunction.
8
valve (check valve) Check it directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
9
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)
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
H-8 Arm moves slowly or lacks power 1

Trouble • Speed or power of arm is low
Related
information

L.H. work equipment control
Malfunction of left PPC valve PPC valve output pressure
1 lever
(arm circuit)
At neutral 0 MPa {0 kg/cm2}
During arm IN operation Min. 2.75 MPa
During arm OUT operation {Min. 28 kg/cm2}
2
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
Malfunction of pump merge- Pump merge-divider valve (main/LS) of control valve may have mal-
3
divider valve (main/LS) function. Check it directly.
Malfunction of arm control Spool of arm control valve (Lo/Hi) may have malfunction. Check it
4
Malfunction of arm control
Pressure compensation valve of arm control valve (Lo/Hi) may have
Possible causes 5 valve (pressure compensa-
malfunction. Check it directly.
and standard tion valve)
value in normal Malfunction of arm control Regeneration valve of arm control valve (Lo) may have malfunction
state 6
valve (regeneration valve) or defective seal. Check it directly.
Malfunction of arm control
Lock valve of arm control valve (Lo) may have malfunction. Check it
7 valve (lock valve)
directly.
(if equipped)
Malfunction of arm control Check valve of arm control valve (Hi) may have malfunction. Check
8
valve (check valve) it directly.
Safety valve for lock valve may have malfunction or defective seal.
9 of safety valve for lock valve
Check it directly.
(if equipped)
Safety-suction valve of arm control valve (Lo/Hi) may have malfunc-
10 of arm control valve (safety-
tion or defective seal. Check it directly.
suction valve)
Malfunction of arm control Quick return valve of arm control valve (Hi) may have malfunction.
11
valve (quick return valve) Check it directly.
Malfunction of LS shuttle LS shuttle valve of right travel control valve, boom control valve, left
12 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.
13 Defective arm cylinder
Arm cylinder Leakage from 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
H-9 Bucket moves slowly or lacks power 1

Trouble • Speed or power of bucket is low
Related
information

R.H. work equipment control
Malfunction of right PPC PPC valve output pressure
1 lever
valve (bucket circuit)
During bucket CURL operation Min. 2.7 MPa
During bucket DUMP operation {Min. 28 kg/cm2}
Malfunction of bucket control Spool of bucket control valve may have malfunction. Check it
2
Possible causes valve (spool) directly.
and standard Malfunction of bucket control
value in normal Pressure compensation valve of bucket control valve may have mal-
state function. 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.
Malfunction of LS shuttle LS shuttle valve of service control valve may have malfunction.
5
valve (service) Check it directly.
6 Defective bucket cylinder
Bucket cylinder Leakage from cylinder
CURL relief 20 cc/min
H-10 Work equipment does not move in its single operation 1

(1) Boom does not move singly.
(2) Arm does not move singly.
Trouble • Work equipment does not move singly (3) Bucket does not move singly.
(4) Bottom dump does not move singly. (For loading
shovel)
Related
information

Possible causes Work equipment control lever PPC valve output pressure
and standard 1 Malfunction of PPC valve
value in normal At neutral 0 MPa {0 kg/cm2}
state Min. 2.75 MPa
Operated
{Min. 28 kg/cm2}
Malfunction of control valve
2 Spool of control valve may have malfunction. Check it directly.
(spool)
PC400, 450-7E0 15
H-11 Work equipment has a bit too fast hydraulic drift 1

Trouble • Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large.
Related
information

Possible causes 1 Defective boom cylinder
Boom cylinder Leakage from cylinder
and standard
value in normal Boom RAISE relief 20 cc/min
state Defect in seal of boom con- Seal of lock valve of boom control valve (Lo) may be defective.
2
trol valve (lock valve) Check it directly.
Defective seal of safety valve
3 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
Trouble • Hydraulic drift of work equipment is large (2) Hydraulic drift of arm is large.
Related
information

1 Defective arm cylinder
Arm cylinder Leakage from cylinder
Arm IN relief 20 cc/min
Possible causes Seal of safety-suction valve of arm control valve (Lo/Hi) may be
and standard defective. Check it directly.
Defective seal of arm control
value in normal 2 (When troubleshooting this safety-suction valve, it is allowed to
valve (safety-suction valve)
state replace it with another one to see the change in phenomena and
judge its acceptability.)
Defective seal of arm control Seal of spool of arm control valve (Lo/Hi) may be defective. Check it
3
Defective seal of arm control
Seal of pressure compensation valve (bottom side) of arm control
valve (Lo/Hi) may be defective. Check it directly.
tion valve)
16 PC400, 450-7E0
Trouble • Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large.
Related
information

1 Defective bucket cylinder
Bucket cylinder Leakage from cylinder
Bucket curl relief 20 cc/min
Possible causes Seal of safety-suction valve of bucket control valve may defective.
and standard Defective seal of bucket con- Check it directly.
value in normal 2 trol valve (safety-suction (When troubleshooting this safety-suction valve, it is allowed to
state valve) replace it with another one to see the change in phenomena and
Defective seal of bucket con- Seal of bucket control valve spool may be defective. Check it
3
trol valve (spool) directly.
Defective seal of valve con-
Seal of pressure compensation valve (bottom side) of bucket control
4 trol valve (pressure compen-
valve may be defective. Check it directly.
sation valve)
PC400, 450-7E0 17
H-12 Work equipment has big time lag 1

Trouble • Time lag of work equipment is large.
Related
information

LS-EPC output
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Possible causes Hi Operated 0 MPa {0 kg/cm2}
and standard
value in normal Malfunction of control valve
Regeneration valve of control valve may have malfunction. Check it
state 2 (regeneration valve)
directly.
[boom and arm only]
Safety-suction valve (Boom: Head side, Arm/Bucket: Bottom side)
of control valve may have malfunction. Check it directly.
Malfunction of control valve
3 (When troubleshooting this safety-suction valve, it is allowed to
replace it with another one to see the change in phenomena and
Malfunction of control valve Pressure compensation valve of control valve may have malfunc-
4
(pressure compensation valve) tion. Check it directly.
H-13 Other work equipment moves when relieving single circuit 1

Trouble • When part of work equipment is relieved singly, other parts of work equipment move
Related
information

and standard Defective seal of control
value in normal Seal of pressure compensation valve of control valve may be defec-
state tive. Check it directly.
tion valve)
H-14 Power max. switch does not operate 1

Trouble • The power maximizing function does not work.
Related
information

Possible causes
and standard Malfunction of 2-stage relief Swing lock switch Solenoid output pressure
1
value in normal solenoid valve OFF 0 MPa {0 kg/cm2}
state
2.84 – 3.43 MPa
ON
{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
H-15 Machine push-up function does not operate. 1

Trouble • Machine push-up function does not operate.
Related
information

Possible causes Machine push-up switch Solenoid output pressure
Malfunction of machine
and standard 1
push-up solenoid valve Min. 2.75 MPa
value in normal OFF
state {Min. 28 kg/cm2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom control Malfunctioning of safety-suction valve (high-voltage set side of head
2
valve (safety-suction valve) side) of boom control valve (Lo) is suspected. Check it directly.
PC400, 450-7E0 19
H-16 In compound operation of work equipment, speed of part loaded

more is low 1
Trouble • In compound operation of work equipment, speed of part loaded more is low.
Related
—
information

Malfunctioning of pressure compensation valve on smaller load side
is suspected. Check it directly.
Combinations in com-
Larger load side Smaller load side
pound operation
Boom RAISE +
Possible causes Boom Arm
Arm IN
and standard
value in normal Malfunction of control valve Boom RAISE +
1 Arm Boom
state on smaller load side Arm OUT
Boom RAISE +
Boom Bucket
Bucket CURL
Arm OUT +
Arm Bucket
Bucket CURL
Boom LOWER +
Arm Boom
Arm OUT
H-17 When machine swings and raises boom simultaneously, boom

rising speed is low 1
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related
• If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
information

and standard
value in normal Malfunction or defective seal LS select valve of control valve may have malfunction or defective
1
state of LS selector valve seal. Check them directly.
H-18 When machine swings and travels simultaneously, travel speed

lowers largely 1
Trouble • When machine swings and travels simultaneously, travel speed lowers largely.
Related
• If speed of single travel operation is also slow, carry out troubleshooting of H-20 first.
information

and standard
value in normal Malfunction of LS shuttle LS shuttle valve of left travel control valve or swing control valve
1
state valve (left travel and swing) may have malfunction. Check it directly.
20 PC400, 450-7E0
H-19 Machine deviates during travel 1

Trouble • Machine deviates during travel.
Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.75 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left Within 0.4 MPa
outputs {Within. 4 kg/cm2}
2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Oil pressure ratio
Defective adjustment or mal- pressure All levers in neutral (Lever operated
3
Possible causes function of LS valve halfway)
and standard Pump discharge
value in normal 1
pressure Almost same
state pressure
LS valve output Approx. 0.6
Malfunction of travel junction Travel lever Solenoid output pressure
4
solenoid valve Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
When either side operated
{29 – 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
5
valve Check it directly.
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
7 Defective travel motor
Travel lever Leakage from travel motor
Travel relief Max. 40 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive (It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.)
PC400, 450-7E0 21
H-20 Travel speed is low 1

Trouble • Travel speed is low.
Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.75 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left/ Within 0.4 MPa
forward and reverse outputs {Within. 4 kg/cm2}
2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
LS-EPC output
Possible causes 3 Malfunction of LS-EPC valve pressure
and standard
Approx. 1.37 MPa
value in normal Lo Neutral
{Approx. 14 kg/cm2}
state
valve (spool)
Pressure compensation valve of travel control valve may have mal-
function. Check it directly.
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of LS shuttle LS shuttle valve of bucket control valve may have malfunction.
7
valve (bucket) Check it directly.
8 Defective travel motor
Travel lever Leakage from travel motor
22 PC400, 450-7E0
H-21 Machine is not steered well or steering power is low 1

Trouble • Machine is not steered well or steering power is low
Related
information

PPC valve output pressure
Malfunction of travel PPC Travel lever
1 (Steering)
valve (steering spool)
Both sides in neutral 0 MPa {0 kg/cm2}
Min. 2.75 MPa
When either side operated
{Min. 28 kg/cm2}
Malfunction of travel junction Travel lever Solenoid output pressure
2
2.84 – 3.43 MPa
Either side operated
{29 – 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
3
valve Check it directly.
4
Possible causes
and standard 2.84 – 3.43 MPa
Operated
value in normal {29 – 35 kg/cm2}
state Malfunction of merge-divider Merge-divider valve of control valve may have malfunction. Check it
5
valve directly.
valve (spool)
Pressure compensation valve of travel control valve may have mal-
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
8
valve (suction valve) directly.
Malfunction of LS shuttle LS shuttle valve of bucket control valve may have malfunction.
9
valve (bucket) Check it directly.
Defect in seal of check valve Seal of check valve of LS pressure sensing part may be defective.
10
of LS pressure sensing part Check it directly.
Seal of safety valve of travel motor may have malfunction. Check it
directly.
Malfunction of travel motor
11 (Motors of same type on forward and reverse sides or on right and
(safety valve)
left sides may be checked by replacing them with each other and
seeing change of condition.)
Check valve of travel motor may have defective seal. Check it
directly.
Malfunction of travel motor
12 (Motors of same type on forward and reverse sides or on right and
(check valve)
left sides may be checked by replacing them with each other and
seeing change of condition.)
PC400, 450-7E0 23
H-22 Travel speed does not change or travel speed is low or high 1
Trouble • Travel speed does not change or travel speed is or low or high
Related
information

Monitoring
[01500]
Lo Fine control 690 mA
Mi (such as releasing 740 mA
Hi decelerator) 0 mA
1 Malfunction of LS-EPC valve
Possible causes LS-EPC output pres-
and standard sure
value in normal Approx. 1.37 MPa
state Lo Neutral
{Approx. 14 kg/cm2}
Solenoid valve out-
Malfunction of travel speed Travel speed Travel lever
2 put pressure
solenoid valve
Lo Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operated
{29 – 35 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may have malfunction. Check
3
(speed shifting section) it directly.
24 PC400, 450-7E0
H-23 Travel system does not move (only one side) 1

Trouble • Travel system does not move (only one side).
Related
information

Defective seal of travel con- Suction valve of travel control valve may have defective seal. Check
1
trol valve (suction valve) it directly.
Defective seal of travel motor Safety valve of travel motor may have defective seal. Check it
2
(safety valve) directly.
Possible causes Defective seal of travel motor Check valve of travel motor may have defective seal. Check it
3
and standard (check valve) directly.
value in normal a Prepare with engine stopped, then run engine at high
state idle and carry out troubleshooting.
Lowering of travel motor out-
4
put Travel lever Leakage from travel motor
PC400, 450-7E0 25
H-24 Upper structure does not swing 1

Trouble • Upper structure does not swing. (1) Upper structure does not swing in either direction.
Related
information

R.H. work equipment
Malfunction of swing holding Solenoid valve output pressure
1 control lever
brake solenoid valve
2.84 – 3.43 MPa
In swing operation
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check
2
(holding brake) it directly.
Possible causes
and standard L.H. work equipment
Swing lock switch Swing relief pressure
value in normal Defective adjustment or mal- control lever
state 3 function of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
{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.
4 Defective swing motor L.H. work equipment
Leakage from swing motor
control lever
Swing relief Max. 11 l/min
Swing machinery may have internal defect. Check it directly.
5 Defective swing machinery (It may be checked by abnormal sound, abnormal heating, metal
26 PC400, 450-7E0
Trouble • Upper structure does not swing. (2) Upper structure swings only in one direction.
Related
information

Malfunction of swing PPC PPC valve output pressure
1 lever
valve
Min. 2.75 MPa
Possible causes In swing operation
{Min. 28 kg/cm2}
and standard
value in normal Malfunction of swing control
2 Spool of swing control valve may have malfunction. Check it directly.
state valve (spool)
Seal of suction valve of swing motor may be defective. Check it
Defective seal of swing directly.
3
motor (suction valve) (Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.)
Seal of check valve of swing motor may be defective. Check it
4
motor (check valve) (Check valves on right side and left side may be checked by replac-
ing them with each other and seeing change of condition.)
PC400, 450-7E0 27
H-25 Swing acceleration or swing speed is low 1

(1) Swing acceleration or swing speed is low in both
Trouble • Swing acceleration or swing speed is low
directions.
Related
information

Malfunction of LS shuttle LS shuttle valves of all control valves may have malfunction. Check
1
valve (all control valves) them directly.
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check
2
(holding brake) it directly.
L.H. work equipment
Defective adjustment or mal- control lever
Possible causes 3 function of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
and standard {285 – 335 kg/cm2}
value in normal If oil pressure does not become normal after adjustment, safety
state valve may have malfunction or internal defect. Check safety valve
directly.
4 Defective swing motor L.H. work equipment control
lever
Swing relief a Max. 11 l/min
28 PC400, 450-7E0
(2) Swing acceleration or swing speed is low in only one

Trouble • Swing acceleration or swing speed is low
direction.
Related
information

1 lever
valve
Min. 2.75 MPa
In swing operation
{Min. 28 kg/cm2}
Possible causes Malfunction of swing control
2 Spool of swing control valve may have malfunction. Check it directly.
and standard valve (spool)
value in normal
Malfunction of swing control
state Pressure compensation valve of swing control valve may have mal-
tion valve)
4
motor (suction valve) (Suction valves on right side and left side may be checked by
5
motor (check valve) (Check valves on right side and left side may be checked by replac-
PC400, 450-7E0 29
H-26 Upper structure overruns remarkably when it stops swinging 1

• Upper structure overruns remarkably when (1) Upper structure overruns remarkably when it stops
Trouble
it stops swinging. swinging in both directions.
Related
information

L.H. work equipment
Defective adjustment or mal- control lever
1 function of swing motor 27.95 – 32.85 MPa
Possible causes (safety valve) ON Swing relief
{285 – 335 kg/cm2}
and standard
value in normal If oil pressure does not become normal after adjustment, safety
state valve may have malfunction or internal defect. Check safety valve
directly.
2 Defective swing motor L.H. work equipment
control lever
Swing relief a Max. 11 l/min
• Upper structure overruns remarkably when (2) Swing acceleration or swing speed is low in only one
Trouble
it stops swinging. direction.
Related
information

1 lever
valve
Min. 2.75 MPa
In swing operation
{Min. 28 kg/cm2}
Possible causes Swing PPC slow return valve may be clogged. Check it directly.
Clogging of swing PPC slow
and standard 2 (Slow return valves on right side and left side may be checked by
return valve
value in normal replacing them with each other and seeing change of condition.)
state
3 Spool may have malfunction. Check it directly.
valve (spool)
4
motor (suction valve section) (Suction valves on right side and left side may be checked by
5
motor (check valve section) (Check valves on right side and left side may be checked by replac-
30 PC400, 450-7E0
H-27 Large shock is made when upper structure stops swinging 1

Trouble • Large shock is made when upper structure stops swinging.
Related
information

L.H. work equipment
1 control lever
valve
Possible causes At neutral 0 MPa {0 kg/cm2}
and standard
Min. 2.75 MPa
value in normal In swing operation
{Min. 28 kg/cm2}
state
Swing PPC slow return valve may have malfunction. Check it
Malfunction of swing PPC directly.
2
slow return valve (Slow return valves on right side and left side may be checked by
Malfunction of swing motor Shockless valve of swing motor may have malfunction. Check it
3
(shockless valve) directly.
H-28 Large sound is made when upper structure stops swinging. 1

Trouble • Large sound is made when upper structure stops swinging.
Related
information

Malfunction of back pres- Back pressure valve of control valve may have malfunction. Check it
1
sure valve directly.
Malfunction of swing motor
2 Safety valve of swing motor may have malfunction. Check it directly.
Possible causes (safety valve)
and standard Seal of suction valve of swing motor may be defective. Check it
value in normal Malfunction of swing motor directly.
state 3
(suction valve) (Suction valves on right side and left side may be checked by
PC400, 450-7E0 31
H-29 Hydraulic drift of swing is large 1

Trouble • 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 posi-
Related
tion, swing holding brake is activated, fixing upper structure with disc brake.
information

Possible causes R.H. work equipment
Malfunction of swing holding Solenoid valve output pressure
and standard 1 control lever
brake solenoid valve
value in normal At neutral 0 MPa {0 kg/cm2}
state
2.84 – 3.43 MPa
In swing operation
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction or inter-
2
(holding brake) nal defect. Check it directly.
Trouble • Hydraulic drift of swing is large. (2) When swing holding brake is released
• When swing holding brake release switch is in emergency position, swing holding brake is released
Related
and upper structure is secured only by oil pressure.
information

Malfunction of swing control Seal of spool of swing control valve may be defective. Check it
1
Seal of pressure compensation valve section of swing control valve
may be defective. Check it directly.
tion valve)
Possible causes
Defective seal of swing
and standard 3 Seal of safety valve of swing motor may be defective. Check it directly.
motor (safety valve)
value in normal
state Defective seal of swing
4 Seal of suction valve of swing motor may be defective. Check it directly.
motor (suction valve)
Defective seal of swing
5 Seal of check valve of swing motor may be defective. Check it directly.
motor (check valve)
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
H-30 Attachment circuit is not changed 1

When attachment is installed
Trouble • 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-pres-
Related sure set.
information 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.

a Prepare with engine stopped, then run engine at high idle and
Malfunction of service return Working mode Solenoid valve output pressure
Possible causes 1
solenoid valve P- or E-mode 0 MPa {0 kg/cm2}
and standard
value in normal 2.84 – 3.43 MPa
B-mode
state {29 – 35 kg/cm2}
Malfunction of service return Service return selector valve may have malfunction. Check it
2
valve directly.
Malfunction of service control Safety valve (B port side) of service control valve may have mal-
3
valve (safety valve) function. Check it directly.
H-31 Oil flow in attachment circuit cannot be controlled 1

When attachment is installed
Trouble • Oil flow in attachment circuit cannot be controlled.
• On a machine equipped with attachment, flow rate in service circuit changes depending on the mode
Related chosen from select mode.
information • Procedure for adjusting flow rate is not identical between P- or E-mode and B-mode. For more infor-
mation, see Operation and Maintenance Manual.

Malfunction of service
1 Service current EPC valve may have malfunction. Check it directly.
current EPC valve
Possible causes a Prepare with engine stopped, then run engine at high idle and
and standard carry out troubleshooting.
value in normal PPC valve output
Malfunction of service PPC Harness connector Service pedal
state 2 pressure
valve
Disconnect V30 con- At neutral 0 MPa {0 kg/cm2}
nector of service cur- 2.75 MPa
rent EPC valve. Operated
{28 kg/cm2}
PC400, 450-7E0 33
SEN03605-01

© 2008 KOMATSU
All Rights Reserved
34
SEN03606-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
Troubleshooting of engine (S-mode)
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 1
S-16 Vibration is excessive ........................................................................................................................... 28
2 PC400, 450-7E0
PC400, 450-7E0 3
Method of using troubleshooting chart 1

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
a 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.)
4 PC400, 450-7E0
PC400, 450-7E0 5
<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 gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 PC400, 450-7E0
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 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Cause
Cracked EGR cooler (Coolant in exhaust piping)

• Defective electrical system
• Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Defective alternator (generator section)

• Insufficient intake of air
Defective alternator (regulator section)

• Improper selection of fuel
Stuck, seized supply pump plunger
Defective intake air heater system
Defective or deteriorated battery

• Coolant in exhaust piping
Clogged feed pump gauze filter

Clogged air cleaner element
Clogged fuel filter, strainer

Worn piston ring, cylinder
a The common rail fuel injection system (CRI) recognizes the fuel injec-
tion timing electrically. Accordingly, even if the starting operation is car-
ried out, the engine may not start until the crankshaft revolves 2 turns
Defective injector
at maximum. This phenomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of
Operated for long period E E E E E
machine
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally w
(if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
While engine is cranked not flow out w w
with starting motor
Check items
If spill hose from injector is disconnected, little fuel spills w

When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
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 q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect gauze filter of feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for failure
q
code.
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 PC400, 450-7E0
*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, how-
ever, it is not a problem.
*2: Failure codes [CA559] and [CA2249]
PC400, 450-7E0 9
S-2 Engine does not start 1

a) Engine does not turn Cause
Cracked EGR cooler (Coolant in exhaust piping)

General causes why engine does not turn
Defective starting motor (safety relay section)

• Internal parts of engine seized:
Defective connection of battery terminal
Defective starting motor (motor section)

See “S-4 Engine stops during operations”
• Coolant entered in cylinder, producing water hammer
Defective or deteriorated battery

• Defective electrical system
Defective starting circuit wiring

• Defective hydraulic pump
Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Degree of use of
Questions
Operated for long period EEE

machine
Condition of horn Horn does not sound Q Q w
when starting switch
is turned ON Horn volume is low w
Battery electrolyte is low w

Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch
is turned to START, Makes grating noise w w
starting pinion moves Soon disengages again w
out, but
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
q
out (*1)
Carry out troubleshooting in H-mode
Carry out troubleshooting in E-mode
Inspect flywheel ring gear directly q

When specific gravity of electrolyte and voltage of battery are measured, they are
q
Troubleshooting
low
There is not voltage (20 – 30 V) between battery relay termi-
q
nal M and terminal E
Turn starting switch When terminal B and terminal C of starting switch are con-
q
OFF, connect cord, nected, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are con-
shooting at ON q
nected, engine starts
Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
—
10 PC400, 450-7E0

PC400, 450-7E0 11
b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (Does not close)

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)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump

Broken supply pump shaft key
Defective supply pump PCV
Malfunction of flow damper

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use
EEE
Questions
Operated for long period

of machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
and Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel does
While engine is not flow out Q Q w Q
cranked with
starting motor If spill hose from injector is disconnected, little fuel
Q w w w w Q
spills

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)”
q q q q
See *1 for failure code.
Carry out troubleshooting for “PCV1 Error (*2) or PCV2 Error (*3).”
q
See *2 or *3 for failure code.
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

12 PC400, 450-7E0
c) Exhaust smoke comes but engine does not start Cause
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
Excessive wear of piston ring, cylinder liner
Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray

Defective, deteriorated battery


Use of improper fuel
Degree of use of
Operated for long period E EE E
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
w w w
nance Manual
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w w
cranked with starting out
motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for failure code. q
When injector is tested alone, condition of spray is poor q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if the gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
PC400, 450-7E0 13
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Cause
Malfunction of flow damper (Leakage from injector is large)

• Defective condition of fuel injection
Seized turbocharger, interference of turbocharger

• 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)
Clogged injector, defective spray


Improper valve clearance
Stuck EGR valve
Degree of use of
Operated for long period EEE E EE
machine
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
w w w
nance Manual
Q w
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Carry out troubleshooting for “EGR Valve Servo Error. (*1)” See *1 for failure code. q
Troubleshooting
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
q q
not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

14 PC400, 450-7E0
S-4 Engine stops during operations 1

General causes why engine stops during operations Cause
Broken dynamic valve system (valve, rocker arm, etc.)

• Seized parts inside engine
• There is overheating
• Defective hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Broken supply pump shaft key

Leaking, clogged fuel piping
Broken, seized feed pump
Defective hydraulic pump

Broken, seized gear train
Degree of use of
Operated for long period EE
machine
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w
Questions
Condition when engine Engine overheated and stopped w Q

stopped Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Check items
Metal particles are found when oil pan is drained w w w Q Q

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q
Inspect crank shaft bearing directly q

Troubleshooting
Inspect gear train directly q
Inspect feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for code. q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
PC400, 450-7E0 15
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Cause
Malfunction of flow damper (Leakage from injector is large)

• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicated)
• Defective EGR valve
• Defective bypass valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Low idle speed is set too low
Malfunction of bypass valve

Malfunction of EGR valve

Degree of use of
Operated for long period EE EE
machine
Questions
Occurs at a certain speed range Q Q Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and
w w
Maintenance Manual
Check items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting for “Bypass Valve Servo Error. (*2)” See *2 for failure code. q
Troubleshooting

q q
does not change
Carry out troubleshooting for “Eng Ne Speed Sensor Error. (*3)” See *3 for
q
failure code.
Carry out troubleshooting for “Eng Bkup Speed Sensor Error. (*4)” See *4 for failure
q
code.
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add

*2: Failure codes [CA1628] and [[CA1629]
*3: Failure code [CA689]
*4: Failure code CA778]
16 PC400, 450-7E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Defective installation of charge air pressure sensor (air leakage)

Defective charge air pressure sensor, wiring harness

Defective fuel temperature sensor, wiring harness

• Defective condition of fuel spray
Clogged injector, defective spray (dirt in injector)

Defective drive of injector (signal, solenoid)

• There is overheating:

See “S-14 Coolant temperature becomes too high (Overheating)”

Air leakage from air intake piping
(limiting injection rate (output) because of an error in electrical system)

Leaking, clogged fuel piping

Degree of use of
machine
Questions
Suddenly Q w Q Q Q
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Maintenance Manual w w
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w Q
Output becomes insufficient after short stop of operation w
Black w w w
Color of exhaust gas
Blue under light load w w
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low w w
Check items

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied w w Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w w
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for “Chg Air Press Sensor High (Low) Error. (*2)” See
*2 for failure code. q
Carry out troubleshooting for “Fuel Temp Sensor High (Low) Error. (*3)” See *3
for failure code. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

PC400, 450-7E0 17
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Cause
Leakage of air between turbocharger and cylinder head


• Supply of fuel is excessive

• Defective condition of fuel spray
Clogged spill piping (on cylinder head side)

• There is overheating:

See “S-14 Coolant temperature becomes too high (Overheating)”

(limiting injection rate (output) because of an error in electrical system)
Improper fuel injection pressure

Improper fuel injection timing
• EGR valve is stuck and is open

(Excessive EGR gas, insufficient intake of air)
Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Stuck EGR valve
Degree of use of
machine
Suddenly became black w Q Q Q
Questions
Color of exhaust
Gradually became black w Q Q Q
gas
Blue under light load w
Oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temper-
Q w
ature of some cylinders is low
Check items

Torque converter stall occurred or pump relief speed is high (Fuel is injected
Q Q
excessively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w
Troubleshooting

When muffler is removed, exhaust gas color improves q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for
q q
failure code.
When a cylinder is cut out for reduced cylinder mode operation, engine
q
speed does not change
Inspect spill piping (on cylinder head side) directly q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error. (*3)”
q
See *3 for code.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

18 PC400, 450-7E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Cause
Turbocharger
• Abnormal consumption of oil
Oil leakage from oil pan, cylinder head, etc.

• Long-time operation of engine at low idle or high idle (Do not run engine
Worn, damaged valve (stem, guide, seal)

at idle for more than 20 minutes continuously)
• External leakage of oil
Oil leakage from EGR valve system

Dust sucked in from intake system
• Wear of parts in lubrication system
Clogged breather, breather hose

Worn seal at turbocharger end
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEEE E

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load Q w w
Amount of blow-by Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnor-
q
mally
Troubleshooting
Excessive play of turbocharger shaft q q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC400, 450-7E0 19
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Cause
Clogged turbocharger lubrication drain tube

• Entry of exhaust gas into oil due to internal wear
Defective seal at turbocharger turbine end

• Clogging of lubrication passage
• Use of improper fuel
• Use of improper oil
Clogged breather, breather hose

• Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Worn EGR valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use of
Operated for long period EEEE
Questions
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates error even when oil temperature is high (if moni-
w Q
tor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Troubleshooting

See S-7
Check breather and breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
20 PC400, 450-7E0
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause

• Leakage of fuel
• Defective condition of fuel injection (fuel pressure, injection timing)
• Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of
Questions
Operated for long period EE E

machine
More than for other machines of same model Q Q Q Q
Condition of fuel con-
Gradually increased Q Q
sumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
w
Check items
Low idle speed is high Q

Torque converter stall occurred or oil pressure pump relief speed is high Q
Black Q Q Q Q
White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error. (*2)” See *2 for fail-
q
ure code.
Check with monitoring function of the machine monitor. q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

PC400, 450-7E0 21
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Cause
Broken O-ring of cylinder liner, holes caused by pitting

• Internal leakage in lubrication system
• Internal leakage in cooling system
Insufficient amount of thrust by cylinder liner

Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
Questions
Degree of use of machine Operated for long period E E

Suddenly occurred Q Q
Increase of oil level
Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Troubleshooting Check items
There are excessive air bubbles in radiator, coolant spurts back w w
Pressure-tightness test of cylinder head shows there is leakage q

Inspect cylinder block, liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
22 PC400, 450-7E0
S-12 Oil pressure drops 1

General causes why oil pressure drops Cause
Defective oil pressure sensor, wiring harness

• Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

• Defective oil pressure control
Defective oil level sensor, wiring harness

• Selection of oil by the temperature etc. specified in the Operation and Main-
Leakage from EGR oil pressure piping

tenance Manual is not observed.
• Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure
monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if monitor is Indicates pressure drop on slopes w
installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve spring of oil pump relief valve is fatigued, damaged q

See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, leaks oil q
Inspect EGR oil pressure piping directly q
Carry out troubleshooting for “Eng Oil Press Sensor High (Low) Error. (*1)”
q
See *1 for failure code.
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
PC400, 450-7E0 23
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Cause
Clogging or defective seal of water pump drain hole (breather hole)

• 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”
Defective seal of accessories (Pump, compressor)

Cracked EGR cooler (Coolant in oil)
Defects in thermostat seat section

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Questions
Degree of use of
Operated for long period 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
Check items
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
q
flows out (*1)
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of accessories directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
24 PC400, 450-7E0

PC400, 450-7E0 25
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Cause

• 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
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
Operated for long period EEE EE
machine
Questions
Condition of over- Suddenly overheated Q Q w Q

heating Always tends to overheat Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed)
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged
w w
with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Inspect EGR cooler for leakage of coolant directly q
Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation test of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
26 PC400, 450-7E0
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Cause
Improper fuel injection timing (abnormality in coolant low temperature sensor)

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise before starting

troubleshooting.
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
a The engine is operated in the low-temperature mode while it is not
Leakage of air between turbocharger and cylinder head

warmed up sufficiently. Accordingly, the engine sound becomes a little
Broken dynamic valve system (valve, rocker lever)

larger. This does not indicate abnormality, however.
Interference of turbocharger, seized turbocharger

a When the engine is accelerated, it is operated in the acceleration mode
Crack of or gas leakage from EGR gas piping

and its sound becomes a little larger for up to about 3 seconds. This does
not indicate abnormality, however.
Removed, seized gear train bushing

Improper gear train backlash
Clogged, seized injector

Dirt caught in injector
Degree of use of Operated for long period E
Questions
machine
Condition of Gradually occurred Q Q
abnormal noise Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w Q

Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is abnormal w
Abnormal noise is loud when engine is accelerated Q Q Q Q
Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q q
Abnormal noise is heard only when engine is started q
Check with monitoring function of the machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
PC400, 450-7E0 27
S-16 Vibration is excessive 1

General causes why vibration is excessive Cause
Misalignment between engine and devices on machine side

• Defective parts (abnormal wear, breakage)
• Misalignment between engine and chassis
• Abnormal combustion
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

a If abnormal noise is made and vibration is excessive, carry out troubleshoot-
Worn main bearing, connecting rod bearing

ing for “S-15 Abnormal noise is made”, too.

Improper gear train backlash
Broken parts inside damper

Worn camshaft bushing
Degree of use of
Questions
Operated for long period E E E

machine
Condition of Suddenly increased Q Q
vibration Gradually increased Q Q Q
Metal particles are found when oil filter is drained w w
a Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check with monitoring function of machine monitor q
Inspect engine mounting bolts and cushions directly q
When alignment is measured, radial runout or facial runout is detected q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Remedy
28 PC400, 450-7E0
PC400, 450-7E0 29
SEN03606-01

© 2008 KOMATSU
All Rights Reserved
30
SEN03608-03
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 1
SEN03608-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
for the following.
79 T-
* *** ****
- :
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 PC400, 450-7E0
50 Disassembly and assembly SEN03608-03
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
* *** ****
79 T- - :
means that they are not available 5 : Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
PC400, 450-7E0 3
Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 PC400, 450-7E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
PC400, 450-7E0 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 PC400, 450-7E0
Special tools list 1

a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
1 795-630-5500 Standard puller t 1

Fuel supply pump 1 2 01010-81080 Bolt t 2 Separation of gear and shaft
3 01643-31032 Washer t 2
2 795-931-1100 Seal puller assembly q 1 Removal of front oil seal
1 795T-521-1140 Push tool t 1 N Q
Engine front oil seal
3 2 01010-61650 Bolt t 3 Installation of front oil seal
3 01643-31645 Washer t 9
4 795-931-1100 Seal puller assembly q 1 Removal of engine rear seal
1 795T-421-1340 Push tool t 1 N Q
A 5 2 01010-61635 Press fitting of standard oil
Bolt t 3
seal (with guide)
3 01643-31645 Washer t 3
1 795-931-1220 Push tool t 1
Engine rear oil seal
6 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 3
Press fitting of sleeved oil seal
1 795T-421-1320 Push tool t 1 N Q
7 2 01010-61645 Bolt t 3
3 01643-31645 Washer t 9
Cylinder head Angle tightening of cylinder
8 790-331-1110 Wrench q 1
assembly head bolt
Removal, installation of
Engine and B 796T-601-1110 Stopper t 1 N Q
engine mounting bolt
hydraulic pump
796-460-1210 Oil stopper q 1
assembly C Stopping of oil
796-770-1320 Adapter q 1
PC400, 450-7E0 7
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 796T-627-1630 Push tool q 1 Q Removal of shaft

2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
790-101-5401 Push tool kit t 1
• 790-101-5531 • Plate 1
Swing motor and 4 Press fitting of oil seal
swing machinery D • 790-101-5421 • Grip 1
assembly • 01010-51240 • Bolt 1
Press fitting of bearing inner
5 790-201-2870 Push tool t 1
race
Press fitting of bearing inner
6 790-201-2770 Push tool t 1
race
7 796T-626-1110 Push tool t 1 Q Press fitting of bearing
796-627-1210 Wrench assembly t 1
• 796-627-1220 • Wrench 1 Removal, installation of round
1
• 796-427-1140 • Pin 3 nut
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
Final drive 791-122-1130 Plate q 1
E
assembly 790-101-2550 Leg q 2
2 790-101-2740 Adapter q 2 Pressing of bearing inner race
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 t}) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1 Installation of floating seal
Carrier roller 791-430-3230 Installer t 1
F
assembly 791-601-1000 Oil pump t 1
Track roller 791-630-1780 Installer t 1
G Supply of oil
assembly 791-601-1000 Oil pump t 1
791-575-1520 Installer t 1
Idler assembly H
791-601-1000 Oil pump t 1
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
Disassembly, assembly of
1 Cylinder
790-101-1600 t 1 recoil spring assembly
(686 kN {70 t})
Recoil spring 790-101-1102 Pump t 1
J
assembly
• 790-201-1660 • Plate 1
2 Installation of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
8 PC400, 450-7E0
New/remodel
Necessity
Symbol
Sketch
Q'ty
791-650-3000 Remover and installer t 1

Track shoe Cylinder
K 790-101-1300 t 1 Pulling out of master pin
assembly (980 kN {100 t})
790-101-1102 Pump t 1
796-946-1310 Guide Ø21.8
1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide Ø20.9
1 1
(For 723-46-44100)
796-946-2210 Guide Ø20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide Ø21.6
1
(For 723-46-42800)
2
Control valve 796-946-2120 Guide Replacement of pressure
L 1
assembly (For 723-46-44100) compensation valve seal
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller t 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly, assembly of
M • 790-101-2540 • Washer 1
assembly center swivel joint assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
PC400, 450-7E0 9
New/remodel
Necessity
Symbol
Sketch
Q'ty
Disassembly, assembly of
1 790-502-1003 Cylinder repair stand t 1
hydraulic cylinder assembly
790-102-4300 Wrench assembly t 1 Removal, installation of piston
2
790-102-4310 Pin t 2 assembly
3 790-720-1000 Expander q 1
Ring (For boom and
796-720-1680 q 1
bucket)
Clamp (For boom and Installation of piston ring
4 07281-01589 q 1
bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
Hydraulic cylinder • Push tool
N • 790-201-1851 1
assembly (For bucket)
• Push tool
• 790-201-1861 1
5 (For boom) Press fitting of bushing
• Push tool (For arm)
• 790-201-1871 1
Ø120
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
6 Press fitting of dust seal
• 790-201-1660 • Plate (For bucket) 1
• 790-201-1670 • Plate (For boom) 1
• 790-201-1680 • Plate (For arm) 1
796-670-1100 Remover q 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
• 796-670-1130 • Screw 1
Work equipment • 796-870-1110 • Adapter 1
P Removal of foot pin
assembly • 01643-33080 • Washer 1
• 01803-13034 • Nut 1
Puller (490 kN {50t},
790-101-4000 q 1
long)
790-101-1102 Pump (294 kN {30t}) q 1
1 796T-416-1010 Push tool t 1 N Q
Travel PPC valve Press fitting of bushing
Q 2 796T-416-1030 Push tool t 1 N Q
assembly
3 796T-416-1020 Push tool t 1 N Q Installation of pin
Operator’s cab 1 793-498-1210 Lifter (Suction cup) t 2 Removal and installation of
Y
glass 2 20Y-54-13180 Adapter t 2 operator’s cab glass
— Impact wrench q 1
Counterweight Removal and installation of
Z Socket wrench (Width
assembly — q 1 counterweight assembly
across flats: 65 mm)
10 PC400, 450-7E0
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A3-1. Push tool
A5-1. Push tool
PC400, 450-7E0 11
A7-1. Push tool
B. Stopper
12 PC400, 450-7E0
D1. Push tool
D7. Push tool
PC400, 450-7E0 13
E2. Push tool
Q1. Push tool
14 PC400, 450-7E0
Q2. Push tool
Q3. Push tool
PC400, 450-7E0 15
SEN03608-03

© 2009 KOMATSU
All Rights Reserved
16
SEN03609-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
50 Disassembly and assembly1

Engine and cooling system
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 .................................................................................... 20
Removal and installation of radiator assembly ............................................................................................. 29
Removal and installation of hydraulic oil cooler assembly ............................................................................ 31
Removal and installation of aftercooler assembly......................................................................................... 33
Removal and installation of engine and hydraulic oil pump assembly .......................................................... 34
PC400, 450-7E0 1
Removal and installation of fuel 8. Disconnect return hose (8) of the fuel supply
supply pump assembly 1 pump.
9. Disconnect the intake air heater harness clamp
(9) and fuel supply pump connectors PV1 (10),
Special tools PV2 (11) and G (12).
10. Remove the fuel supply pump high-pressure
Necessity
pipe clamp (13) and 2 boots (13A). [*1]
Symbol
Sketch
Q’ty
N/R
Part number Part name a Common rail side not visible sheltered by
the fuel filter.
1 795-630-5500 Standard puller t 1
A 1 2 01010-81080 Bolt t 2
3 01643-31032 Washer t 2
Removal
k Disconnect the negative (–) terminal from bat-
tery.
1. Open the engine inspection cover.

2. Remove undercover (radiator, engine).
3. Remove cover (1).
4. Remove fan guard (2).
5. Remove air intake hose (3).
11. Remove 2 high-pressure pipes (14) at the fuel
supply pump outlet port. [*2]
6. Loosen adjustment nut (5) and locknut (6) and

remove V-belt (7) from the pulley.
7. Disconnect harness connector (M34), remove 12. Disconnect inlet tube (15) of the fuel supply
the bracket mounting bolts, remove air condi- pump. [*3]
tioner compressor assembly (4) and deposit
them on the floor cover.
2 PC400, 450-7E0
13. Disconnect feed pump inlet tube (16) and out- 16. Remove nut (21) and washer (22).
let tube (17) to remove lubrication tube (18). a Take care not to drop the removed parts
into the gear case. [*4]
14. Remove fuel supply pump bracket (19) from

the engine bottom. 17. Set the tools A1, A2, A3 as follows.
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 3
2) Align the tapped hole (hole for inserting 18. Remove the fuel supply pump mounting bolts
the removal bolt) of supply pump drive (23). Press the shaft of the pump using a tool and
gear to the mounting bolt hole of the cover remove the fuel supply pump assembly (24). [*5]
(cover (20) removed in step 15). a Take care not to drop the pump.
a Rotate the crankshaft to about the a Leave the tool applied until the pump is
middle (b) between the damper 2- installed. [*6]
5TOP 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.
4 PC400, 450-7E0
Installation [*4]
a Carry out installation in the reverse order to 3 Gear mounting nut:
removal. 127 – 147 Nm {13 – 15 kgm}
a Match the key and keyway to install.
[*1]
Tighten clamp (13) with the hand first, and then [*5]
tighten it permanently. 3 Joint bolt of pump side:
3 Clamp mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*6]
[*2] 2 Mounting bolt: Gasket sealant (LT-2)
k Don't correct high-pressure tube by bend-
ing it for re-use. q Fuel leak check
k Always use genuine clamp for fixing high- Refer to the paragraph on the "Checking fuel
pressure pipe. Strictly observe the tighten- circuit for leakage” in Testing and adjusting,
ing torque requirements. and check the fuel system for any leakage
accordingly.
a Check the following matters before installing
high-pressure pipe. If there is any abnormality, q Air bleeding
replace the high-pressure tube to prevent pos- Refer to the paragraph on the "Bleeding air
sible fuel leakage. from fuel circuit" in Testing and adjusting, and
bleed the air accordingly.
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.
q 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.
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]
3 Joint bolt of tube (15):
25.5 – 34.3 Nm {2.5 – 3.5 kgm}
PC400, 450-7E0 5
Removal and installation of fuel 5. Remove clamp (4) and remove air intake tube
injector assembly 1 (5). [*1]
Removal
k Disconnect the negative (–) terminal from
battery.
1. Drain coolant.
6 Coolant: 36 l
2. Close the fuel stopper valve on the fuel tank.
3. Remove connector (P24), overflow tube (1)

and sub-tank (2).
6. Remove the clamp and disconnect hose (9)
4. Remove the mounting bolt and then hoist the between the radiator and the engine at the
engine hood assembly (3) to remove. radiator side. [*2]
4 Engine hood: 200 kg 7. Remove covers (6), (7), and fan guard (8).
8. Remove oil filter (10). (Leave the tube unre-

moved)
9. Remove fuel pre-filter (11).

(after disconnecting the hose, put it at the left
side of the engine)
10. Remove priming pump (12).
(after disconnecting the hoses, let each hose
put on the left-hand side of the engine)
6 PC400, 450-7E0
11. Remove fuel main filter (13).

(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine. [*3]
15. Remove clamp (23), bolts (24) and bracket (25)

to remove the housing complex (diffuser) (26).
12. Disconnect the terminal of intake air heater

harness (14).
a Disconnect the clamp.
13. Remove the air intake connector (15).
16. Disconnect injector harness connectors (27) (at 6

places), remove the clamp and shift the harness
to the lower left-hand side of the engine. [*5]
a For how to remove the connector, see the
“Removal and installation of cylinder head
14. Disconnect the connector EGR (16), SEGR assembly”.
(17), TIM boost temperature (18), wiring clamp 17. Remove clamps (28) and boots (29). [*6]
(19), PIM boost pressure sensor (20), PAMB 18. Remove the clamp and 6 high-pressure injec-
atmospheric sensor (21) and connector (22). tion tubes (30). [*7]
a Remove harness clamps.
a Place removed parts together under the
engine. [*4]
PC400, 450-7E0 7
19. Remove head cover (31). [*8] 22. 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.
20. Removal of injector harness.

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]
21. 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).
8 PC400, 450-7E0
Installation q Install high-pressure tubes between the com-

a Carry out installation in the reverse order to mon rail and fuel injector according to the fol-
removal. lowing instructions:
1) Install high-pressure pipes (70), (71), (72),
[*1] (73), (74) and (75).
3 Hose clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm} a Mounting angle of the high-pressure
injection pipe is adjusted when the
[*2] injector is installed.
3 Radiator-related hose clamp 3 Sleeve nut (on both sides):
(9): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 39.2 – 49 Nm {4 – 5 kgm}
2) Install bracket (76) and clamp (77) and
[*3] tighten by hand first, and then tighten
3 Fuel filter joint bolt: them permanently.
24.5 – 34.5 Nm {2.5 – 3.5 kgm} 3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*4] [*5] 3) Install clamps (78), (79), (80) and (81).
Keep the harness assembly and other harnesses 10 4) Install 6 each splash prevention covers
mm and above away from the high-pressure tube. (82) and (83).
a Direct the slit on the injector side
[*6] [*7] downward and that on the common
k Don't correct high-pressure tube by bend- rail side toward the cylinder block.
ing it for re-use.
k Always use genuine clamp for fixing high-
pressure pipe. Strictly observe the tighten-
ing torque requirements.
a Check the following matters before installing

high-pressure pipe. If there is any abnormality,
replace the high-pressure tube to prevent pos-
sible 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.
q 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 9
5) Install bracket (84). 2) Install gasket (91) and O-rings (92) and (93) to
3 Mounting bolt: injector (85).
11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2 O-ring: Engine oil (EO30)
6) Install clamps (78), (79), (80) and (81).
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
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
[*8] pipe insertion hole.
3 Head cover mounting bolt
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*9]
a Tighten 2 harness capture nuts to the injector
alternately.
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24
kgm}
[*10]
a Tighten the mounting bolt of harness holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
[*11] 4) Fit the ball washer to bolt (88) and tighten

3 Mounting nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm} holder (87) temporarily.
2 Spherical part of washer:
[*11] Engine oil (EO30)
a Install the injector as follows. 5) Locate high-pressure sleeve (89) to inlet con-
a Check that the inside of the injector sleeve is nector (90) and then tighten them temporarily.
free from dirt. a Tighten the common rail side sleeve nut
1) Loosen the mounting bolt of common rail (85). temporarily, too.
6) Tighten holder (87) permanently using bolt
(88).
a Tighten bolt while pulling the tube of the
high-pressure pipe in the opposite direc-
tion to the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the high-
pressure sleeve from the inlet connector and
then install the other injectors sequentially by
following the above procedure.
10 PC400, 450-7E0
8) Tighten the common rail mounting bolt.

3 Common rail mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
q 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 Coolant: 36 l
q 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.
q 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
Removal and installation of 5. Remove fan (6).

engine front seal 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Seal puller
2 795-931-1100 q 1
assembly
A 1 795T-521-1140 Push tool t 1 N Q
3 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 9
6. Remove fan belt (7) and the air compressor

Removal belt (8). [*1]
1. See the paragraphs for the “Removal and
installation of radiator”, “Removal and installa- 7. Sling the damper and pulley assembly (9) and
tion of hydraulic oil cooler”, and “Removal and then remove it by loosening 6 mounting bolts.
installation of aftercooler” to remove the radia- 4 Damper and pulley assembly: 25 kg
tor, hydraulic oil cooler and the aftercooler.
2. Remove covers (1) and fan guard (2).
8. Remove engine front seal as follows.

a Before removing the seal, drive in it a little
3. Loosen the air compressor assembly mounting to separate.
bolts and loosen adjustment nuts (3). a Take care not to damage the front cover
(10) and the seal contact surface of crank-
4. Loosen alternator assembly adjustment nuts shaft (11).
(4) and adjustment bolt guide (5). a If front seal (12) cannot be removed easily,
remove it according to the following proce-
dure.
1) Drill several holes about 3 mm in
diameter into front seal (12).
a Remove all the chips completely.
2) Replace the tip of tool A2 with the
drill-type tip and insert it to drilled
hole.
3) Put the tool A2 and remove the front
seal with impacts of slide hammer
[SH].
12 PC400, 450-7E0
a Take care not to damage crank- Installation

shaft (11).
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)
q Tool A2
2. Install tool A3-1 and tighten 3 bolts (A3-2) until

they stop to press fit front seal (12) to front
cover (10). (Left side of figure)
a Do not fit washers to bolts (A3-2).
3. Remove 3 bolts (A3-2), fit 3 washers (A3-3)

each to them, and tighten them again evenly to
press fit front seal (12) until the end of tool A3-
1 reaches the end of front cover (10). (Right
side of figure)
a Press fitting distance (b) of front seal from
front cover end: 16 (+1/0) mm
PC400, 450-7E0 13
q Carry out installation in the reverse order to

removal.
[*1]
q Adjust the belt tension. For details, see Test-
ing and adjusting, “Checking and adjusting fan
belt and alternator belt tension” and “Checking
and adjusting air conditioner compressor belt
tension”.
14 PC400, 450-7E0
Removal and installation of 5. Remove engine rear oil seal (2).

engine rear seal 1 a Before removing the seal, drive in it a little
to separate.
a Take care not to damage the seal contact
Special tools faces of flywheel housing (3) and crank-
shaft (4).
Necessity
Symbol
Sketch
a If it is difficult to remove the seal, remove it
Q’ty
N/R
Seal puller
4 795-931-1100 q 1
assembly
1 795T-421-1340 Push tool t 1 N Q
5 2 01010-61635 Bolt t 3
3 01643-31645 Washer t 3
A 1 795-931-1220 Push tool t 1
6 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 3
1 795T-421-1320 Push tool t 1 N Q
7 2 01010-61645 Bolt t 3
3 01643-31645 Washer t 9
• A5: Press fitting of standard seal (with guide)
• A6, A7: Press fitting of sleeved seal
Removal of standard seal
Removal 1) Drill several holes about 3 mm in diameter
1. Remove hydraulic pump assembly by reading into engine rear oil seal (2).
the paragraph for the “Removal and installation a Remove all the chips.
of hydraulic pump assembly.” 2) Replace the tip of tool A4 with the drill-
type tip and insert it in one of the holes
2. Remove the damper. drilled in the above step.
3) Pull hammer [SH] of tool A4 toward you
3. Sling the flywheel (2) by leaving a flywheel and remove the engine rear seal with
mounting bolt (1) unremoved. impact forces.
a Perform the above procedure at sev-
4. Sling the flywheel (2) to remove.
eral places so that the seal will not
4 Flywheel assembly: 60 kg slant.
k 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.
PC400, 450-7E0 15
Removal of sleeved seal Installation

1) Replace the tip of tool A4 with the hook- Selection of seal
type tip and hitch it to outer case (a) of a Select the “standard” or “sleeved” engine rear
engine rear oil seal (2). oil seal.
2) Pull hammer [SH] of tool A4 toward you a Decide which oil seal to select by feeling the
and remove the engine rear seal with wear of the oil seal contact surface of the
impact forces. crankshaft with the finger cushion.
a Perform the above procedure at sev- q If wear (level difference) is not felt:
eral places so that the seal will not Standard seal
slant. q If wear (level difference) is felt:
3) Cut and remove sleeve (5) with a chisel Sleeved seal
and a hammer.
a Take care not to damage crankshaft
(4).
a Remove all the chips.
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 (b) of the slash part. Wipe off the
oil from the crankshaft.
a Never remove guide (6) installed to standard
seal (2) before installing the rear seal.
16 PC400, 450-7E0
1. Set large inside diameter side (c) of guide (6) 4. Install tool A5-1 and tighten 3 bolts (A5-2)
of engine rear oil seal (2) to the end of crank- evenly until they stop to press fit engine rear oil
shaft (4). seal (2).
a Take care not to mistake the installed a Do not fit washers to bolts (A5-2).
direction. a When press fitting the seal, take care not
to damage the seal lip with the tool, etc.
5. Remove 3 bolts (A5-2), fit 1 washer (A5-3)

each to them, and tighten them again evenly to
press fit engine rear oil seal (2) until the end of
tool A5-1 reaches the end of crankshaft (4).
a Press fitting distance (d) of seal from
crankshaft end: 16.3 ± 0.2 mm
a When press fitting the seal, take care not
to damage the seal lip with the tool, etc.
a After press fitting the seal, remove the red
sealant layer from its periphery.
2. Push in the outer case end of engine rear oil

seal (2) evenly.
3. After press fitting engine rear oil seal (2) in the

degree that it does not drop from housing,
remove guide (6).
a When removing the guide, take care not to
damage the seal lip.
PC400, 450-7E0 17
Procedure for installing sleeved seal 2. Apply sleeve (5) to sleeve and seal assembly
a Clean, degrease, and dry the contact face (2) to the end of crankshaft (4) and tighten 3
against the flywheel housing. bolts (A6-2) of tool A6-1 evenly to press fit
a Check that the end corners of the crankshaft, sleeve and seal assembly (2).
lip sliding surfaces, and housing are free from a Fit 1 washer (A6-3) each to bolts (A6-2),
flaws, burrs, rust, etc. and tighten them until the end of tool A6-1
a Do not apply oil or grease to the crankshaft touches the end of crankshaft (4).
and the inside cylinder of sleeve (5) and seal
lip (b) of the slash part. Wipe off the oil from the
crankshaft.
a Handle the engine rear oil seal (2) and sleeve
as an assembly and never separate them.
3. Remove tool A6 and interchange with tool A7-

1. Tighten 3 bolts (A7-2) evenly until the end of
tool A7-1 touches the end of crankshaft (4) to
press fit sleeve and seal assembly (2).
a Do not fit washers to bolts (A7-2).
1. Set sleeve and seal assembly (2) to tool A6-1.
2 Sleeve inside cylinder surface: 4. Remove 3 bolts (A7-2), fit 3 washers (A7-3)
Gasket sealant (LG-7) each to them, and tighten them again evenly to
press fit sleeve and seal assembly (2) until the
end of tool A7-1 reaches the end of crankshaft
(4).
a Press fitting distance (e) of sleeve and seal
assembly from crankshaft end:
16.3 ± 0.2mm
a After press fitting the seal, remove the red
sealant layer from its periphery.
18 PC400, 450-7E0
a Carry out the following installation in the

reverse order to removal.
[*1]
a Tighten the flywheel mounting bolts in the
order shown in the following figure.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time : 147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
a After installing the flywheel, measure the facial

runout and radial runout with dial gauge [1].
q Radial runout: Max. 0.30 mm
q Facial runout: Max. 0.30 mm
PC400, 450-7E0 19
Removal and installation of 4. Remove clamp (4) and remove air intake tube
cylinder head assembly 1 (5). [*1]
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
A8 790-331-1110 Wrench q 1
Removal
battery.
1. Drain coolant.
6 Coolant: 36 l 5. Remove the clamp and disconnect hose (9)
between the radiator and the engine at the
radiator side. [*2]
2. Disconnect connector (P24) and overflow tube
(1) and remove the sub-tank (2). 6. Remove covers (6), (7), and fan guard (8).
3. Remove the mounting bolt and then hoist the

engine hood assembly (3) to remove.
4 Engine hood: 200 kg
7. Remove the exhaust pipe cover (10) and the

muffler cover (11).
20 PC400, 450-7E0
8. Remove clamp (12) and two clamps (13) of 13. Disconnect the terminal of intake air heater
muffler. Shift the muffler (14) to remove the harness (19).
joint tube (15) and the muffler (14). a Disconnect the clamp, too.
9. Remove oil filter (80). (Leave the tube unre-

moved) 15. Disconnect the connectors EGR (21), SEGR
(22), TIM boost temperature sensor (23), wir-
ing clamp (24), PIM boost pressure sensor
(25), PAMB atmospheric sensor (26) and con-
nector (27).
a Remove clamps.
a Place removed parts together under the
engine. [*4]
10. Remove the fuel pre-filter (16).

(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
11. Remove priming pump (17).
(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
12. 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]
PC400, 450-7E0 21
16. Remove clamp (28), bolt (29) and brackets 19. Remove clamp (34) and boots (35) to remove
(30) to remove the housing complex (diffuser) 6 high-pressure injection tubes (36). [*4] [*8]
(31).
17. Remove brackets (behind the front hanger)
(32).
18. Disconnect injector harness (33) and move it

to the lower left-hand side of the engine.
20. 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 screw-
driver [1] to the stepped portion (a), then mov-
ing the driver in the direction of (X) while
pressing stopper of (b).
22 PC400, 450-7E0
21. Sling the air intake manifold assembly (42),

remove 24 mounting bolts to remove the 24. Remove tubes (45) (for taking out EGR exhaust
assembly. gas).
4 Air intake manifold: 25 kg
25. Remove EGR valve inlet tube cover (46).

22. Remove hose (43).
PC400, 450-7E0 23
26. Remove exhaust manifold heat insulation covers 30. Remove spill tube (51). [*9]
(47).
31. Remove air vent tube (52). [*10]
27. Disconnect turbocharger lubrication inlet tube

(48) and disconnect the drain tube (49). [*6] 32. Remove head cover (53). [*11]
28. Sling the turbocharger and exhaust manifold 33. Remove the injector harness as follows. [*12]
assembly (50), and remove the mounting bolts. 1) Fully loosen two capture nuts (55) on the
[*7] head of injector (54).
a Loosen nuts alternately.
29. Remove turbocharger and exhaust manifold 2) Loosen bolt (56) of harness fixing holder.
assembly by hoisting. 3) Disconnect injector harness (55a).
4 Turbocharger and exhaust manifold
assembly: 40 kg
24 PC400, 450-7E0
34. Remove rocker arm assembly (57). [*13] 37. Remove 12 crossheads (65). [*15]
1) Loosen locknut (58) and then loosen
adjustment screw (59) completely.
2) Remove mounting bolt (60) and then
rocker arm and shaft assembly (57).
38. Removal of injector harness connector

1) Remove mounting bolt (67) of harness
connector (66).
2) Remove holder (69) from the harness.
35. Remove 12 push rods (61).
3) Remove harness connector (70) by push-

36. Remove holder mounting bolt (63) of injector ing it outward from inside of rocker hous-
(62) and then remove injector along with ing (71).
holder (64). [*14] 4) Remove O-ring (72) from the rocker hous-
a Do not try to grip the solenoid valve at the ing.
top of the injector using a pliers and the
like.
PC400, 450-7E0 25
39. Remove rocker housing (71). [*16] Installation

removal.
[*1]
3 Hose clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm}
[*2]
3 Radiator-related hose clamp:
3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
[*3]
3 Fuel filter joint bolt:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
40. Removal of cylinder head assembly [*17] [*4]

1) Remove each set of 7 mounting bolts (74) Keep the harness assembly and other harnesses
of cylinder head assembly (73). 10 mm and above away from the high-pressure
2) Using eyebolt [1], lift and remove cylinder tube.
head assembly (73).
4 Cylinder head assembly: 20 kg [*5]
Tighten the air intake manifold assembly mounting
3) Remove each head gasket. bolts in the order given below.
3 Intake manifold assembly:
59 – 74 Nm {6 – 7.5 kgm}
[*6]
3 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}
26 PC400, 450-7E0
[*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 clear-
ance.
Pointer is located under the cover.
q Valve clearance
Intake : 0.33 mm
Exhaust : 0.71 mm
a See the paragraph of “Adjusting valve clear-
ance” in the part for Testing and adjusting for
the valve clearance instructions.
[*8] 3 Rocker arm locknut:
a For details on and how to install the high-pres- 58.8 – 73.5 Nm {6 – 7.5 kgm}
s u r e tu be c o v e r, s ee P a r a gr a p h [ * 5] i n
"Removal and installation of fuel injector [*14]
assembly." For the mounting instructions of injector and holder,
see the paragraph for the "Removal and installation
High-pressure tube installation instructions of fuel injector assembly."
a Don't correct high-pressure tube by bending it
for re-use. [*15]
1) Tighten high-pressure tube permanently. a Amply apply engine oil (EO30-CD) to cross-
3 Sleeve nut: head guide and crosshead top face.
39.2 – 49 Nm {4 – 5 kgm} a Adjust the crosshead according to the follow-
2) Temporarily tighten high-pressure clamp and ing procedure.
brackets all by hand. 1) Loosen the locknut fully and return the
3) Tighten high-pressure tube clamp perma- adjustment screw.
nently. 2) Holding the top of the crosshead lightly,
3 Clamp nut:
tighten the adjustment screw while keep-
11.8 – 14.7 Nm {1.2 – 1.5 kgm} ing the crosshead in contact with the valve
stem.
4) Tighten bracket permanently.
3) After the adjustment screw touches the
5) Install cover.
valve stem, tighten it further by 20°.
a Direct the slit to the side of cylinder head.
4) Tighten the locknut at this position.
3 Locknut:
6) Temporarily install gate-type bracket and cover
(also working as clamp).
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
7) Tighten the cover permanently.
3 Cover mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm} [*16]
3 Rocker housing mounting bolt:
8) Tighten the gate-type bracket permanently.
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*9]
3 Spill tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*10]
3 Air vent tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*11]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*12]
a Tighten the capture nuts of the harness alter-
nately.
3 Capture nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
PC400, 450-7E0 27
[*17] a When not using tool A8

a Clean the bottom face, block top face and liner After applying a paint marking (b) to the cylin-
with dry cloth or soaked with a solvent. der head and bolt, tighten the bolt by 90° to
a Replace a bolt having 5 punch marks to the 120° (target 120°).
bolt head. a After tightening bolts 1 – 6, tighten auxiliary
a Tighten the bolt with hand and screw in to the bolt 7.
block by turning the bolt at least 2 rounds. 3 Cylinder head mounting auxiliary bolt:
2 Bolt threaded portion and under side of 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
the bolt head:
LM-P or engine oil (EO30-CD) a After tightening the bolt, punch a mark (c) on
a Tighten the cylinder head mounting bolts in the its head.
order indicated in the figure. a When using a new bolt, do not punch a mark
3 Cylinder head mounting bolt 1 – 6: on its head.
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.
q Feed coolant
coolant level.
5 Coolant: 36 l
28 PC400, 450-7E0
Removal and installation of

radiator assembly 1 5. Remove the clamp and hoses (6), (7), (8) and
(9) between the radiator and the engine. [*1]
Removal 6. Remove radiator front cover (10).

the battery.
1. Remove covers (1) and (2).
7. Remove undercover.
9. Disconnect the lower hose (12).
2. Drain coolant.
6 Coolant: 36 l
(3) and remove the sub-tank (4).
10. Remove 2 upper mounting bolts (13).
PC400, 450-7E0 29
11. Lift and remove radiator assembly (14). Installation

4 Radiator assembly: 30 kg q Carry out installation in the reverse order to
removal.
q Feed coolant
coolant level again.
5 Coolant: 35 l
[*1]
3 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}
30 PC400, 450-7E0

hydraulic oil cooler assembly 1
Removal
k Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
battery.
5. Remove covers (5) and (6).
2. Remove cover under the hydraulic oil tank

drain plug. Remove the hydraulic oil tank drain
hose plug to drain hydraulic oil. 6. Remove tube (8).
6 Hydraulic oil: 248 l Remove drain plug (7) and then remove fuel
tube (8) after draining oil inside.
a Open the hydraulic oil tank cap before
draining to release the tank inner pres-
sure. Then drain oil from the cooler hose.

(2) and remove the sub-tank (3).
PC400, 450-7E0 31
7. Remove 3 hydraulic oil cooler left-side mount- Installation

ing bolts (9) and remove a hydraulic oil cooler q Carry out installation in the reverse order to
front mounting bolt (10). removal.
8. Remove 4 butterfly screws (11) from the
screen. q Oil fill (hydraulic oil tank)
9. Disconnect upper piping (12). Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circu-
late 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
32 PC400, 450-7E0
Removal and installation of 9. Extract hoses (9) and (10) from the cooler
aftercooler assembly 1 while pushing down the aftercooler assembly
(8). [*1]
10. Hoist the cooler assembly with nylon slings,
Removal etc. before the hose is completely extracted.
k Disconnect the negative (–) terminal from Withdraw the hose and pull out the aftercooler
battery. assembly sideway to remove.
1. Open the radiator front cover. 4 Aftercooler assembly: 25 kg
2. Remove undercover (1).
3. Remove cover (2) under the aftercooler.

Installation
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. Remove evaporator (3) with the bracket as a

unit.
5. Remove plate (4).
6. Remove grease gun holder (5).
7. Loosen hose clamp (6).
8. Remove mounting bolt (7).
a: Dimension
b: Lapped portion of bridge and band
c: Bridge
d: Punch hole
a Apply lubricant (Three-Bond band 18B) to the
threaded portion and tighten the bolt.
PC400, 450-7E0 33
Removal and installation of 3. Close the fuel stopper valve on the fuel tank.
engine and hydraulic oil pump
assembly 1 (1) and remove the sub-tank (2).
Special tools 5. Remove the mounting bolt and then hoist the
Necessity
4
Symbol
Sketch
Engine hood: 200 kg
Q’ty
N/R
B 796T-601-1110 Stopper t 1 N Q
1 796-460-1210 Oil stopper q 1
C
2 796-770-1320 Adapter q 1
Removal
k Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
battery.
a Take care not to mistake installation position of
each piping by attaching tags, etc.
1. Drain coolant.
6 Coolant: 36 l
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 Hydraulic oil: 248 l
6. Remove floor cover (4) on the control valve.

a Remove cover (4) to remove the following
covers (5) through (8).
34 PC400, 450-7E0
7. Remove covers (5), (6), (7) and (8). 10. Disconnect hose (15) under the radiator.
a After removal, place the floor cover to
original position and temporarily tighten
the bolt.
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. Remove undercovers (13) and (14).
PC400, 450-7E0 35
13. Remove fan (23). 17. Remove the terminal of intake air heater har-
ness (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 condi-
tioner compressor (28) and deposit them on
the floor cover.
36 PC400, 450-7E0
20. Remove engine controller cover (35). 25. Disconnect return hose (41) and the clamp.
a Attach fuel stopper plug to the hose.
21. Disconnect engine controller connectors CE02

(36) and CE03 (37). [*4] 26. Disconnect the turbocharger hose (42).
22. Remove harness clamp (38) at two locations. 27. Disconnect the car heater hose (43).
23. Remove grounding T11 (39).
24. Disconnect oil level sensor connectors (40)
and (P44).
PC400, 450-7E0 37
28. Disconnect alternator wiring B (44), R (45) and 32. Remove grounding harness (51) (between
E (46). engine and frame).
29. Disconnect the car heater hose (47).
33. Remove hydraulic pump piping.

30. Remove harness clamps (48) at 3 locations q (52) EPC source pressure port hose
and grounding T12 (49). (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 loca-

tions.
q (61) V22 (PC-EPC solenoid valve)
31. Disconnect starter terminal B (50) and M7 con- (Collar band: Red)
nector. q (62) V21 (LS-EPC Solenoid valve)
(Collar band: White)
38 PC400, 450-7E0
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.
PC400, 450-7E0 39
Installation
removal.
[*1]
3 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]
3 Hose clamp:
9.8 ± 0.5 Nm {100 ± 5 kgcm}
[*3]
a See the paragraph for the “Checking and
adjusting air conditioner compressor belt ten-
sion” in Testing and adjusting or the paragraph
for the "Removal and installation of engine
front seal".
[*4]
3 Connector screw:
2.82 ± 0.28 Nm {0.288 ± 0.035 kgm}
[*5]
3 Engine mount bolt:
824 – 1030 Nm {84 – 105 kgm}
q Feed coolant
coolant level again.
5 Coolant: 36 l
q Oil feed (hydraulic oil tank)

Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circu-
late the piping. Check the oil level again.
5 Hydraulic oil: 248 l
q Air bleeding
Refer to the paragraph on the "Bleeding air
from various parts" in Testing and adjusting.
40 PC400, 450-7E0
PC400, 450-7E0 41
SEN03609-02

© 2008 KOMATSU
All Rights Reserved
42
SEN03610-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Power train
Removal and installation of travel motor and 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 machinery assembly .......................................................................... 12
Removal and installation of swing circle assembly ....................................................................................... 19
PC400, 450-7E0 1
Removal and installation of travel 4. Remove the 24 mounting bolts and lift off the
motor and final drive assembly 1 final drive assembly (6). [*1]
a Take care extremely not to damage the
nipple sealing faces of the hose joints.
Removal a When slinging the final drive assembly, do
1. Remove the sprocket. For details, see not use the tap hole for the cover.
“Removal and installation of sprocket”.
k Lower the work equipment to the 4 Final drive assembly: 700 kg
ground and stop the engine. Then,
loosen the hydraulic oil filler cap
slowly to release the internal pressure
of the hydraulic tank.
k Disconnect the negative (–) terminal
from battery.
Installation
removal.
[*1]
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
3. Disconnect drain hose (2), travel speed selec-
tor hose (3), and motor hoses (4) and (5). q Refilling with oil (Hydraulic tank)
a Remove the nipples, too. 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.
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
2 PC400, 450-7E0
Disassembly and assembly of 2) Using eyebolt [2], remove cover (1).

final drive assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R

• 796-627-1220 • Wrench 1
1
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1 3. Spacer
791-122-1130 Plate q 1 Remove spacer (2).
E
790-101-2550 Leg q 2
2 790-101-2740 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
3 796-627-1020 Installer t 1
Disassembly
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case. 4. No. 1 carrier assembly
6 Final drive case: 11 l 1) Remove No. 1 carrier assembly (3).
2. Cover
1) Place the final drive on block [1] and
remove the mounting bolts.
PC400, 450-7E0 3
2) Disassemble the No. 1 carrier assembly 7. No. 2 carrier assembly

according to the following procedure. 1) Sling No. 2 carrier assembly (15) with
i) Push in pin (5) to drive out shaft (6) wires, etc. and remove it.
from carrier (7).
a After removing the shaft, remove
pin (5).
ii) Remove thrust washer (8), gear (9),
bearing (10), and thrust washer (11).
2) Disassemble No. 2 carrier assembly

i) Push in pin (16) to drive out shaft (17)
from carrier (18).
a After removing the shaft, remove
5. Sun gear pin (16).
Remove spacer (4), No. 1 sun gear (12), and ii) Remove thrust washer (19), gear
No. 2 sun gear (13). (20), bearing (21), and thrust washer
(22).
6. Thrust washer 8. Nut

Remove thrust washer (14). 1) Remove lock plate (23).
4 PC400, 450-7E0
2) Using tool E1, remove nut (24). ii) Remove floating seal (27) from hub
(32).
9. Hub assembly
1) Using eyebolts [3], remove hub assembly iii) Remove bearings (28) and (29) from
(25) from the travel motor. hub (32).
2) Disassemble hub assembly (25) accord- 3) Remove floating seal (30) from travel
ing to the following procedure. motor (31).
i) Remove bearing (26) from hub (32).
PC400, 450-7E0 5
4) Using puller [4], remove bearing (34) and

collar (33) together.
a You can remove bearing (34) and col-
lar (33) without using puller [4] in
some cases.
3) Install collar (33) and bearing (34) to travel

motor (31).
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).
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 O-
ring 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 sur-
faces.
2) Using tool E3, install floating seal (27) to

hub (32).
a Thoroughly degrease and dry the O-
ring 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 sur-
faces.
6 PC400, 450-7E0
5) Using eyebolts [3], set hub assembly (25) 6) Under the condition in 5) above, measure
to the travel motor. Using the push tool, dimension (a).
lightly hit the bearing to press fit it.
7) Measure thickness (b) of nut (24).

2. Nut 8) Obtain (a) – (b) = (c).
Install the nut according to the following proce- 9) Using tool D1, tighten nut (24) until dimen-
dure. sion (c) is as follows.
1) Rotate the hub 2 – 3 turns. a Dimension (c): c +0.07–0.03 mm
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}
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 maxi-
mum force at the beginning of rota-
tion.
PC400, 450-7E0 7
11) Install lock plate (23), fitting it to the motor a After assembling the carrier assem-
spline. bly, check that the gear (20) turns
2 Threads of mounting bolt: smoothly.
Adhesive (LT-2)
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
2) Install No. 2 carrier assembly (15).

a Install No. 2 carrier assembly (15) so
that the 4 gear shaft ends will be in
3. No. 2 carrier assembly the 4 hollows at the motor case end.
1) Assemble the No. 2 carrier assembly
a There is a caulking mark made when
the pin was inserted at the end of car-
rier side hole (h) and the inside wall of
the hole is swelled at that mark. Flat-
ten 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. Thrust washer
Install thrust washer (14).
ii) 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 wash-
ers.
iii) Insert pin (16).
a After inserting the pin, caulk the
pin part of the carrier.
8 PC400, 450-7E0
5. No. 2 sun gear ii) Aligning the pin holes of shaft (6) and
Install spacer (4) and No. 2 sun gear (13). carrier, lightly hit the shaft with a plas-
tic hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care
not to damage the thrust wash-
ers.
iii) Insert pin (5).
a After inserting the pin, caulk the
pin part of the carrier.
a After assembling the carrier assem-
bly, check that the gear (9) turns
smoothly.
6. No. 1 carrier assembly

a There is a caulking mark made when
the pin was inserted at the end of car-
rier side hole (h) and the inside wall of
the hole is swelled at that mark. Flat-
i) Install bearing (10) to gear (9) and fit
an d ( 11) , an d th en set t he ge ar
assembly to carrier (7). 2) Install No. 1 carrier assembly (4).
PC400, 450-7E0 9
7. No. 1 sun gear shaft 9. Cover

Install No. 1 sun gear shaft (12). Using eyebolts [2], install cover (1) and tighten
the mounting bolts.
8. Spacer
Install spacer (2). 2 Cover mounting face:
Gasket sealant (LG-6)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a After installing spacer (2), measure dis-

tance (j) from the top of planetary gear (9)
to the top of hub assembly (25) and check
the assembly condition. q Refilling with oil
q Dimension (j): 1.2 mm a Tighten the drain plug and add engine oil
a If dimension (j) is less than 1.2 mm or the (EO30-CD, or SHC 5W-30K for extremely
top of planetary gear (9) is projected from cold district) through the oil filler.
the top of hub assembly (25), they are not
5 Final drive case: 11 l
assembled correctly. In this case, check
again. a After installing the final drive assembly to
the chassis, check the oil level again at
the specified position.
10 PC400, 450-7E0
Removal and installation of swing

motor and swing machinery
assembly 1
Removal
k Release the residual pressure in the
hydraulic circuit. Refer to the “Releasing
residual pressure from hydraulic circuit”
section in the Testing and adjusting chap-
ter 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 3. Lift and remove swing motor and swing
LOCK position. machinery assembly (6).
k Disconnect the negative (–) terminal from a When lifting the swing motor and swing
battery. machinery assembly for removal, do so
slowly so that the hoses and other parts
1. Disconnect five swing motor hoses (1) through will not be damaged.
(5). a Take good care, when lifting the assembly,
q (1): Between swing motor and control until the spigot joint portion is pulled out.
valve (MA port)
(2): Between swing motor and control
4
q
Swing motor and swing machinery
valve (MB port)
assembly: 550 kg
q (3): Suction hose (S port)
q (4): Drain hose (T port)
q (5): Swing brake releasing pilot hose (B
port)
Installation
q Install in reverse order of removal.
2. Disconnect the swing motor and swing
machinery assembly (6), using forcing screw [*1]
[1] after removing the mounting bolts. [*1] 3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
q 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.
q Air bleeding
Refer to the “Bleeding air from various parts” in
the Testing and adjusting chapter of this man-
ual.
PC400, 450-7E0 11
Disassembly and assembly of 3. No. 1 sun gear

swing machinery assembly 1 Remove No. 1 sun gear (2).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 796T-627-1630 Push tool q 1 Q

2 790-201-2350 Push tool t 1
3 790-201-2510 Push tool t 1
• 790-101-5531 • Plate 1
D 4
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1 4. No. 1 carrier assembly
1) Remove No. 1 carrier assembly (3).
5 790-201-2870 Push tool t 1
6 790-201-2770 Push tool t 1
7 796T-626-1110 Push tool t 1 Q
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from
the swing machinery case.
6 Swing machinery case: 21 l
2. Swing motor assembly

1) Set the swing motor and swing machinery
assembly on block [1]. 2) Disassemble the No. 1 carrier assembly
2) Remove 10 mounting bolts and lift off according to the following procedure.
swing motor assembly (1). Remove snap ring (4), and then remove
shaft (5), gear (6), bearing (7), thrust
4 Swing motor assembly: 115 kg washer (8), and plate (9).
12 PC400, 450-7E0
5. Ring gear 8. No. 2 carrier assembly

Remove the mounting bolts and ring gear (10). 1) Lift off No. 2 carrier assembly (13).
6. No. 2 sun gear 2) Disassemble the No. 2 carrier assembly

Remove No. 2 sun gear (11). according to the following procedure.
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).
7. Bolt
Remove holder mounting bolt (12).
9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of
cover assembly (22).
PC400, 450-7E0 13
2) Turn over case and pinion assembly (24) 11. Bearing

and set it on the press stand. Using push Using multiple push tools [3], remove bearing
tool [2], D1 and the press, pull out pinion (30) from case (31).
shaft assembly (25). a Push tool to be set contact with bearing:
a Set a wood block under the press so D2
that the pinion shaft will not be dam-
aged when it comes off.
a A rough standard pressing force is 20
odd tons.
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
10. Disassemble the pinion shaft assembly (25) engine oil before installing.
1) Using the push tool, remove cover assem- 1. Bearing
bly (22) and bearing (26) from shaft (27). Using push tool D3 and [4], press fit bearing
a A rough standard pressing force is 30 (26) to case (31).
tons. a A rough standard pressing force is several
2) Remove oil seal (28) from cover (29). tons.
14 PC400, 450-7E0
2. Cover assembly 3. Case assembly

1) Using push tool D4, press fit oil seal (28) 1) Turn over case assembly (32) and set it to
to cover (29). shaft (27). Using push tools D5 and D6 [5],
2 Periphery of oil seal: press fit the bearing inner race.
Gasket sealant (LG-6) a When setting the case assembly to
a Take care that the gasket sealant the shaft, take care extremely not to
(LG-6) will not stick to the oil seal lip damage the oil seal.
and shaft. a A rough standard pressing force is 30
tons.
2) Install cover assembly (22) to case (31)

and tighten mounting bolts (23). 2) Bearing
a Match the oil path of cover (22) to the Using too D7, press fit bearing (30).
drilled hole of case (31). a Press both inner race and outer race
2 Cover fitting face: of the bearing simultaneously. Do not
Gasket sealant (LG-6) press only the inner race.
3 Mounting bolt:
a A rough standard pressing force is 20
98 – 123 Nm {10 – 12.5 kgm} odd tons.
a After press fitting the bearing, check
2 Oil seal lip: Grease (G2-LI)
that the case turns smoothly.
PC400, 450-7E0 15
4. No. 2 carrier assembly a When inserting the pin, do not set the
1) Assemble the No. 2 carrier assembly 3 claws (a) on the periphery to the
according to the following procedure. thin part of the carrier (b).
a There is a caulking mark made when The thin part may be on the opposite
the pin was inserted at the end of car- side, however. Check each carrier
rier side hole (a) and the inside wall of and avoid setting a claw to the thin
the hole is swelled at that mark. Flat- part.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit
and (20), and then set the gear
assembly to carrier (16).
a After inserting the pin, caulk the pin

part of the carrier.
5. Bolt and O-ring

1) Tighten bolt (12).
iii)Aligning the pin holes of shaft (15) 2 Threads of mounting bolt:
and carrier, lightly hit the shaft with a Adhesive (LT-2)
plastic hammer, etc. to install. 3 Mounting bolt:
a When installing the shaft, revolve the 343 – 427 Nm {34 – 43.5 kgm}
planetary gear and take care not to
damage the thrust washers.
iv) Insert pin (14).
2) Fit the O-ring to case.
16 PC400, 450-7E0
6. No. 2 sun gear

Install No. 2 sun gear (11).
a Degrease the mating faces of ring gear

(10) and case (29).
7. Ring gear a Never stick gasket sealant to the mating
Using the eyebolt (M12 x 1.75), install ring faces of ring gear (10) and case (29).
gear (10). 3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Add engine oil (EO30-CD) at this time.
8. No. 1 carrier assembly

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.
a 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
iii) After installing plate (9), install thrust a Take care not to install the No. 1 sun gear
washer (8), bearing (7), gear (6), and upside down.
snap ring (4). a 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 fig-
ure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear (10).
2 Mating faces of swing motor

assembly (1) and ring gear (10):
3 Mounting bolt:
9. No. 1 sun gear assembly 98 – 123 Nm {10 – 12.5 kgm}
Install No. 1 sun gear (2). 4 Swing motor assembly: 115 kg
q 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 Swing machinery case: 21 l
18 PC400, 450-7E0
Removal and installation of swing Installation

circle assembly 1 q Carry out installation in the reverse order to
removal.
Removal [*1]
1. Remove the revolving frame assembly. For 2 Mating face of swing circle:
details, see “Removal and installation of Gasket sealant (LG-6)
2 Threads of swing circle mounting bolt:
revolving frame assembly”.
Adhesive (LT-2)
3 Swing circle mounting bolt:
2. Sling swing circle assembly (1) by 3 points
temporarily, remove 40 mounting bolts, and lift
824 – 1,030 Nm {84 – 105 kgm}
off the swing circle assembly. [*1]
Target: 927 Nm {94.5 kgm}
4 Swing circle assembly: 600 kg 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 chas-
sis as shown below.
2 Quantity of grease in grease bath:
Grease (G2-LI), 33 l
(Use GLT2-LI for 50°C specification)
PC400, 450-7E0 19
SEN03610-02

© 2008 KOMATSU
All Rights Reserved
20
SEN03611-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Undercarriage and frame
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 1
Disassembly and assembly of q Floating seal

carrier roller assembly 1 a When installing the floating seal, thor-
oughly clean, degrease, and dry the con-
tact surfaces of the O-ring and floating
a Only precautions for assembling the carrier seal (hatched parts). Take care that dirt
roller assembly are explained below. will not stick to the floating seal contact
surfaces.
Special tools a Be sure to use the installer F to insert the
floating seal assembly in the housing.
Necessity
a After installing the floating seal, check that
Symbol
Sketch
Q’ty
N/R
Part number Part name its slant is less than 1 mm and its projec-
tion (a) is 5 – 7 mm.
1 791-430-3230 Installer t 1
F
2 791-601-1000 pump t 1
4 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}. q Carrier roller
a Using tool F, apply the standard pressure
to the oil filler to check the seal for air leak-
age.
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}
2 PC400, 450-7E0
a Using tool F, fill the carrier roller assembly

with oil and tighten the plug.
5 Carrier roller: 170 – 180 cc (EO30-CD)
PC400, 450-7E0 3
Disassembly and assembly of q Track roller

track roller assembly 1 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
a Only precautions for assembling the track 10 seconds and check that the pointer of
roller assembly are explained below. the gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 791-630-1780 Installer t 1
G
2 791-601-1000 Oil pump t 1
4 Track roller assembly: 75 kg (Single)

85 kg (Double)
Assembly
q Floating seal a Using tool G, fill the track roller assembly
a When installing the floating seal, thor- with oil and tighten the plug.
oughly clean, degrease, and dry the con-
5 Track roller:
tact surfaces of the O-ring and floating
280 – 310 cc (Single) (EO30-CD)
seal (hatched parts). Take care that dirt
280 – 290 cc (Double) (EO30-CD)
will not stick to the floating seal contact
surfaces. 3 Plug: 10 – 20 Nm {1 – 2 kgm}
a Be sure to use the installer G to insert the
its slant is less than 1 mm and its projec-
4 PC400, 450-7E0
Disassembly and assembly of 4. Remove floating seal (7) on the opposite side
idler assembly 1 from idler (5) and shaft and support assembly
(6).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
791-575-1520 Installer t 1
H
791-601-1000 Oil pump t 1
4 Idler assembly: 230 kg
Disassembly
5. Remove nut (8), pull out bolt (9), and then
remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
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 assem-

bly (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 5
Assembly a When installing the floating seal, thor-

1. Press fit bushings (12) (on both sides) to idler oughly clean, degrease, and dry the con-
(5). tact surfaces of the O-ring and floating
seal (hatched parts). Take care that dirt
2. Fit the O-ring and install support (10) to shaft will not stick to the floating seal contact
(11) with bolt (9) and tighten nut (8). surfaces.
a Be sure to use the installer H to insert the
its slant is less than 1 mm and its projec-
a Install the shaft with the UP mark up.
4. Install shaft and support assembly (6) to idler

(5).
3. Using tool H, install floating seal (7) to idler (5)

and shaft and support assembly (6).
5. Similarly, using too H, install floating seal (4) to

idler (5) and support (3).
6 PC400, 450-7E0
a Coat the sliding surface of the floating seal

with oil and take care that dirt will not stick
to it.
a 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 Quantity of oil:
Approx. 345 ± 10 cc (EO-30CD)
3 Plug: 130 – 180 Nm {13 – 18 kgm}
PC400, 450-7E0 7
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring assembly 1 assembly (1).
2. Disassembly of recoil spring assembly

Special tools 1) Set tool J1 to recoil spring assembly (1).
k Since the installed load of the spring is
Necessity
larg e and dangerous, set t he tool
Symbol
Sketch
Q’ty
N/R
Part number Part name securely.
a Installed load of spring:
791-685-8006 Compressor t 1 239.037 kN {24,375 kg}
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 t 1
(680 kN {70 t})
J 790-101-1102 Pump t 1
790-201-1500 Push tool kit 1
• 790-201-1660 • Plate 1
2
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
4 Recoil spring (Excluding idler): 900 kg
Disassembly 2) 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
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
3. 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).
8 PC400, 450-7E0
Assembly 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
1. Assembly of piston assembly

1) Install ring (15) and U-packing (14) to pis-
ton (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 cylin-
der (7).
4) Remove recoil spring assembly (1) from
tool J1.
3. 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 cyl-
inder, bleed air, and check that the grease
flows out of the grease hole.
PC400, 450-7E0 9
Removal and installation of Installation

sprocket 1 q Install in reverse order of removal.
[*1]
Removal 2 Thread of sprocket mounting bolt:
1. Remove track shoe assembly. For details, see Gasket sealant (LG-6)
3
“Removal and installation of track shoe assem- Sprocket mounting bolt:
bly”. 640 – 785 Nm {65 – 80 kgm}
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 Sprocket: 70 kg
10 PC400, 450-7E0
Expansion and installation of 4. Using tool K, remove master pin (1). [*3]
track shoe assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Remover and
791-650-3000 t 1
installer
K Cylinder
790-101-1300 t 1
(980 kN {100 t})
790-101-1102 Pump t 1
5. Move the master pin forward and set block [1]

Expansion of track shoe under the track shoe in front of the idler.
1. Start the engine and set the master pin to
above the idler. 6. Pull out pusher K.
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.
7. Move the machine in reverse slowly to expand

the track shoe. [*4]
PC400, 450-7E0 11
Installation of track shoe 2 Apply grease to the contact faces of

q Carry out installation in the reverse order to dust seal (5) and bushing (4) (all over
expansion. the end face of the dust seal or bushing)
(parts marked O). Do not apply grease
[*1] to the pars marked (X), however.
2 Mounting bolt: Anti-seizure compound R: Detail of regular pin position
( M A R U Z E N M O LY M A X N o . 2 o r M: Detail of master pin position
equivalent) (Pins are not inserted, however)
3 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°.
[*2]
a Adjust the tension of the track shoe. For
detail, see Testing and adjusting, “Check-
ing and adjusting track shoe tension”.
3 Tightening torque for lubricator:

58.8 – 88.3 Nm {6 – 9 kgm}
[*3]
a Using the tool, press fit the master pin so [*4]
that its projection (a) will be as follows. Set the track shoe and sprocket (4) as shown
q Dimension (a): 4.4 ± 2 mm in the following figure (on both right and left
sides).
2 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
12 PC400, 450-7E0

revolving frame assembly 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.
1. Remove the work equipment assembly. For

details, see “Removal and installation of work
equipment assembly”.
2. Remove the counterweight assembly. For 6. Disconnect 7 hoses (5) – (11).

details, see “Removal and installation of coun- q (5): Center swivel joint (Port D) – Swing
terweight assembly”. motor (Port T)
q (6): Center swivel joint (Port D) – Hydrau-
3. Disconnect 4 boom cylinder hoses (1). lic tank
a Plug the hoses to stop oil. q (7): Center swivel joint (Port E) – Sole-
noid 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)
7. Pull out pin (12) on the center swivel joint side

and disconnect the lock plate from the center
swivel joint.
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 oppo-
site side similarly.
4 Boom cylinder assembly: 360 kg
PC400, 450-7E0 13
8. Remove 29 mounting bolts (13), leaving 3 Installation

each at the front and rear sides. q Carry out installation in the reverse order to
removal.
[*1]
q 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 inter-
fere with the center swivel joint assem-
bly.
4 Revolving frame assembly: 10,000 kg
14 PC400, 450-7E0
3 Revolving frame mounting bolt

1. 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.
a Marks (P) and (S) are the soft zone points.
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
again.
q Bleeding air
Bleed air from the travel motor. For details, see
Testing and adjusting, “Bleeding air from vari-
ous parts”.
PC400, 450-7E0 15
Removal and installation of 4. Lift off counterweight assembly (1). [*2]

counterweight assembly 1 a Check where shims have been used.
a When lifting off the counterweight, take
care not to strike it against the engine,
Special tools radiator and cooler assembly, etc.
4
Necessity
Counterweight assembly: 9,500 kg
Symbol
Sketch
Q’ty
N/R
— Impact wrench q 1
Z Socket wrench
— (Width across flats: q 1
65 mm)
a Use the impact wrench and socket wrench

applicable for the tightening torque for the
counterweight mounting bolts.
3 Mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
Removal
k Disconnect the negative terminal (–) from the
battery. Installation
1. Open engine inspection cover at the counter- removal.
weight side. a If heat insulation cover (3) of the engine
a Because the handle of the cover touches compartment is flattened, replace it.
the counterweight.
2. Set eyebolt [1] to counterweight assembly (1).
3. Remove 4 mounting bolts (2). [*1]
[*1]
2 Threads of mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exte-
rior 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.
16 PC400, 450-7E0
PC400, 450-7E0 17
SEN03611-02

© 2009 KOMATSU
All Rights Reserved
18
SEN03612-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 ......................................................................... 23
PC400, 450-7E0 1
Removal and installation of center q (14): Center swivel joint (A port) – Left
swivel joint assembly 1 travel control valve (A2 port)
q (15): Center swivel joint (C port) – Right
travel control valve (A5 port)
Removal
k Release the remaining pressure in the 3. Pull out pin (16) on the side of center swivel
hydraulic circuit. For details, see Testing joint and remove the jam plate from the center
and adjusting, “Releasing residual pres- swivel joint.
sure from hydraulic circuit”.
battery.
a Mark all the piping with tags to prevent mis-
takes in the mounting position when installing.
1. 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 4. Remove four mounting bolts (17).
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)
5. Remove center swivel joint assembly (18). [*1]

4 Center swivel joint assembly: 40 kg
2. Disconnect nine hoses (7) through (15).

q (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) – Hydrau-
lic tank
q (11): Center swivel joint (E port) – Sole-
noid 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)
2 PC400, 450-7E0
Installation
removal.
[*1]
Install the center swivel joint facing in the direc-
tion shown in the diagram.
(The diagram shows the machine as seen from
above.)
q Refilling with oil (hydraulic tank)

through the system. Then check the oil level
again.
q Bleeding air
Bleed the air from the travel motor. For details,
see Testing and adjusting, “Bleeding air from
various parts”.
PC400, 450-7E0 3
Disassembly and assembly of 1. Remove cover (1).

center swivel joint assembly 1
2. Remove snap ring (2).
Special tools 3. Using tool M, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name 4. Remove seal (6) from swivel shaft (5).
790-101-2501 Push puller q 1 5. Remove O-ring (7) and slipper seal (8) from
790-101-2510 • Block 1 swivel rotor (4).
790-101-2520 • Screw 1
791-112-1180 • Nut 1
M 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
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}
4 PC400, 450-7E0
Removal and installation of 6. Disconnect block (7) together with return hose.
hydraulic tank assembly 1
Removal
1. Remove 3 lower covers (1).
7. Disconnect drain hoses (8), (9), and (10).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).

2. Drain the oil from the hydraulic tank.
6 Capacity of hydraulic tank:
Approx. 335 l
3. 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]
5. Disconnect drain hoses (5) and (6).
PC400, 450-7E0 5
13. Lift off hydraulic tank assembly (16). Installation

4 Hydraulic tank assembly: 200 kg q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
254.2 – 308.9 Nm {25.0 – 31.5 kgm}

again.
5 Capacity of hydraulic tank: 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
q Bleeding air
various parts”.
6 PC400, 450-7E0
Removal and installation of q (11): Port PR hose (Solenoid)

control valve assembly 1 q (12): Port PR hose (Pump, yellow)
q (13): Port PP1 hose (Front pump)
q (14): Port PP2 hose (Rear pump)
Removal q (15): Port T hose (Oil cooler)
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.
battery.
a 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).

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
3. Remove partition covers (3), (4), and (5) Boom RAISE (Hose band: Green)
between the engine and control valve. Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm OUT (Hose band: Yellow)
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)
PC400, 450-7E0 7
10. Disconnect 4 boom hoses (24). 15. Disconnect the following 6 right PPC hoses.
q (30): Bucket DUMP (Hose band: Black)
11. Remove boom tube clamps (25) and (26). 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). 16. Disconnect the following 3 control valve hoses.
After removing the hoses from ports B, remove a Do not disconnect hose C.
port A3 tube (Boom bottom side). q (36): Port BP5 hose (To solenoid)
Remove port A4 hose (Swing motor port MB). q (37): Port PX2 hose
Disconnect port A5 hose (Swivel joint port C). q (38): Port TS hose
Remove port A6 tube (Arm head side).
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).
8 PC400, 450-7E0
17. Sling control valve assembly (40) temporarily Installation

and remove 3 mounting bolts (39). q Carry out installation in the reverse order to
removal.

again.
q Bleeding air
various parts”.
18. Lift off control valve assembly (40).

4 Control valve assembly: 250 kg
PC400, 450-7E0 9
Disassembly and assembly of Replacement procedure for pressure compen-

control valve assembly 1 sation valve seal
a Since there many types of the pressure com-
pensation valves, make a mark on each valve
a Only precautions for assembling the pressure
to indicate from where it was removed.
compensation valve assembly and control
valve assembly are explained below.
1. Remove piston (2), plug (3), and spring (4)
from pressure compensation valve (1).
Special tools
2. Remove seal (5) and O-ring (6) from piston (2).
Necessity
Symbol
Sketch
Q’ty
N/R
796-946-1310 Guide Ø21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide Ø20.9
1 1
(For 723-46-44100)
796-946-2210 Guide Ø20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide Ø21.6
1
(For 723-46-42800) a There are many types of the pistons.
2
796-946-2120 Guide a Clean the pressure compensation valve
L 1 thoroughly. Then, using the tool, install
(For 723-46-44100)
seals as shown in the figure.
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500) 3. Fit O-ring (6) to piston (2).
796-946-1330 Sleeve
1 4. Set tool L1 to piston (2) and push it in with your
(For 723-46-40100, 723-46-40601)
hand slowly so that seal (5) will expand evenly.
796-946-1430 Sleeve
1 a You may push in the seal to the flat part of
(For 723-46-42800) the tool first, and then install the tool to the
3
796-946-2130 Sleeve piston and push in the seal further.
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
10 PC400, 450-7E0
5. Set tool L2 to piston (1) for other seal (3) and Assembly
push it in with your hand slowly so that seal (3) q Apply engine oil to the sliding surfaces of the
will expand evenly. parts before installing.
a You may push in the seal to the flat part of q When installing spools (7) and (10) in the valve
the tool first, and then install the tool to the chamber, direct drilled holes (8) and (11)
piston and push in the seal further. toward cylinder ports (9) and (12).
6. 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.
q Install filters (13) to the bottom of ports PLS1

and PLS2 as shown below.
7. 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
3 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}
q 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.
q 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}
q Merge-divider valve
2 Mating face of merge-divider valve:
SEALEND 242 or equivalent
q Tighten the mounting bolts of the merge-
divider valve similarly to those of the control
valve covers.
3 Mounting bolt of merge-divider valve:

156.9 – 176.5 Nm {16 – 18 kgm}
q 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.
12 PC400, 450-7E0
q Pressure compensation valve

a When installing each pressure compensa-
tion valve, check the mark made when it
was removed.
q Main relief valve assembly

After installing the main relief valve to the con-
trol valve, see Testing and adjusting, “Measur-
ing and adjusting oil pressure in work
equipment, swing, and travel circuits”.
PC400, 450-7E0 13

hydraulic pump assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
796-460-1210 Oil stopper q 1

C
796-770-1320 Adapter q 1
Removal
k Disconnect the negative (–) terminal from 3. Drain the oil from the flywheel housing.
the battery.
k Lower the work equipment to the ground 4. Open the main pump side cover.
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the 5. Open the engine hood.
internal pressure of the hydraulic tank.
a Put tags to the disconnected hoses and tubes 6. Lift off covers (2) and (3) together.
to prevent a mistake in re-connecting them.
1. Remove 2 lower covers (1).
8. Remove stay (5).
2. 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 Hydraulic tank: 335 l
14 PC400, 450-7E0
9. Disconnect the following 2 pump wiring con- 11. Sling hydraulic pump assembly (18) tempo-
nectors. rarily and remove 12 mounting bolts (17).
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 12. Lift off hydraulic pump assembly (18). [*1]
(Band color: Red)
q (15): Front pump pressure input port hose 4 Hydraulic pump assembly: 255 kg
q (16): Pump suction port tube
PC400, 450-7E0 15
Installation
removal.
[*1]
2 Hydraulic pump involute spline:
Anti-friction compound (LM-G)
2 Mating face of hydraulic pump case:
q Refilling with oil

3 Flywheel housing drain plug:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}
level.

again.
5 Capacity of hydraulic tank: 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
q Bleeding air
various parts”.
16 PC400, 450-7E0
Removal and installation of oil Installation

seal in hydraulic pump input shaft1 q Carry out installation in the reverse order to
removal.
Removal [*1]
1. Remove the hydraulic pump assembly. Refer 2 Oil seal lip portion: Grease (G2-LI)
to the “Removal of hydraulic pump assembly” 2 Oil seal outer circumference: Grease (G2-LI)
section. a Coat the oil seal outer circumference
thinly with grease.
2. Remove snap ring (1) and then remove spacer a Press-fit oil seal (3), using tool [1].
(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 17
Disassembly and assembly of work equipment PPC valve assembly 1
a Only precautions for assembling the work Assembly

equipment PPC valve assembly are explained a The head of plug (2) must not be projected
below. from the body (1) surface.
3 Plug (2): 6 – 11 Nm {0.6 – 1.1 kgm}
Disassembly a When installing plug (3) to body (1), check the
a Spring (6) and spring (7) consist of each one of insertion depth so that the tip of plug does not
two types of springs with different installed enter the inside Ø20 hole of the body.
loads in four places, so check the mounting 3 Plug (3): 4 – 9 Nm {0.4 – 0.9 kgm}
position (oil pressure port) and mark with tags a Install spring (5) with its small diameter side on
to prevent mistakes when installing. the shim (4) side.
q Diameter of spring (Inside diameter)
Small diameter side: Ø4.9 mm
Large diameter side: Ø5.55 mm
a When installing springs (6) and (7), note that
they are different and they must be installed to
different hydraulic ports.
q Installed height: 31.8 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}
a When installing piston (8), apply grease (G2-
LI) to its outside and the inside of the body (1)
hole.
3 Bolt (11):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
18 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. 648)
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}
a Apply grease (G2-LI) to the sliding parts of joint

(12) and contact surfaces of disc (13) and pis-
ton (8).
2 Quantity of grease (G2-LI)
1) Sliding parts of joint: 2 – 4 cc/periphery
2) Contact surfaces of disc and piston:
0.3 – 0.8 cc/place
a 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.
a See Testing and adjusting, "Adjusting play
of work equipment and swing PPC valve".
a Tighten nut (14) to the following tightening
torque.
3 Nut (14): 69 – 88 Nm {7 – 9 kgm}
PC400, 450-7E0 19
Disassembly and assembly of

travel PPC valve assembly 1
Special tool 5. Remove mounting bolt (10) to remove plate

(22).
New/Remodel
a Check the thickness and the mounting

Symbol
Necessity
Part No. Part name position of washer (18).

Sketch
a Remove pin (23) from body (1).

Q'ty
1 796T-416-1010 Push tool t 1 N Q 6. Remove seal (9) and collar (8).

Q 2 796T-416-1030 Push tool t 1 N Q
7. Remove piston (7) to remove retainer (6),
3 796T-416-1020 Push tool t 1 N Q springs (5) and (4) and shim (3).
a Store shim (3) after checking the thickness
Disassembly and the number of shims at each mount-
1. Remove screw (20) and damper assembly ing position.
(16).
8. Remove valve (2) from body (1).
2. Remove mounting bolt (21) to remove case
(12), shaft (14) and lever (15) assembly.
3. Remove pin (3).
4. Remove lever (15), bushing (10), (11) and

shaft (14) from the case.
20 PC400, 450-7E0
Assembly 2) Using tool Q2, insert busing (11) in case.

Only the precautions for assembling the travel PPC a Insert the bushing (11) from the 10°
valve assembly are described. chamfered side.
a Insert bushing (11) so that dimension
a When assembling, clean and inspect the parts (b) will be as follows.
closely and take care fully so that dirt, rust, q Dimension (b): 0 mm
flaw, etc. will not cause a trouble. a Do not drive the pin with direct impact
loads of a hammer etc.
a When installing piston (7), apply grease (G2-
LI) to its outside and the inside of the body
hole.
a Install spring (4) with its small diameter side on

the shim (3) side.
q Diameter of spring (Inside diameter)
Small diameter side: 4.9 mm, Large diam-
eter side: 5.55 mm
a Assemble shaft (14) in the following procedure.

1) Using tool Q1, insert bushing (10) in case.
a Insert the bushing (10) from the 10°
chamfered side.
a Insert bushing so that dimension (a) 3) Insert lever (15).
will be as follows. 4) Insert shaft (14).
q Dimension (a): 20.4 ± 0.3 mm 5) Using tool Q3, insert pin (13).
a Do not drive the bushing with direct a Insert pin (13) so that dimension (c)
impact loads of a hammer etc. will be as follows.
q Dimension (c): 0 – 0.5 mm
a Do not drive the pin with direct impact
loads of a hammer etc.
PC400, 450-7E0 21
aApply grease (G2-LI) to the rocking part of

shaft (14) and the contact surfaces of lever
(15) and piston (7) and the contact surfaces of
damper (16) and pin (17).
2 Quantity of grease (G2-LI)
Rocking part of shaft: 4 – 8 cc/periphery
Contact surfaces of lever (15) and piston (7):
0.3 – 0.8 cc/place
Contact surfaces of damper (16) and pin
(17): 0.3 – 0.8 cc/place
a Install washer (18) 1.6 mm thick first. If the dif-

ference between both sides at the stroke end
of the lever exceeds 0.7°, change the washer
thickness to reduce the difference to below
0.7°. (If the washer thickness is reduced by
0.3 mm, the stroke end angle is increased by
0.39°.)
q Thickness of washer (t):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.

q Bolt (19): 27 – 34 Nm {2.8 – 3.5 kgm}
q Screw (20):
0.441 – 0.558 Nm {0.045 – 0.06 kgm}
q Bolt (21): 25 – 31 Nm {2.5 – 3.2 kgm}
q Bolt (24): 19.6 – 27.4 Nm {2.0 – 2.8 kgm}
q Plug (25): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (26): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Plug (27): 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
q Plug (28): 4 – 9 Nm {0.4 – 0.9 kgm}
q Plug (29): 6 – 11 Nm {0.6 – 1.1 kgm}
q Plug (30):
1.27 – 1.67 Nm {0.13 – 0.17 kgm}
22 PC400, 450-7E0
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Piston rod assembly
1) Remove the piping from the cylinder
assembly.
Special tools 2) Remove the mounting bolts and discon-
nect cylinder head assembly (1).
Necessity
Symbol
Sketch
3) Pull out piston rod assembly (2).
Q’ty
N/R
a Put a container under the cylinder to
receive oil.
Cylinder repair
1 790-502-1003 t 1
stand
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring (For boom
796-720-1680 q 1
and bucket)
Clamp (For boom
4 07281-01589 q 1
and bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
• Push tool 4) Disassemble the piston rod assembly
• 790-201-1851 1
(For bucket)
N • Push tool i) Set piston rod assembly (2) to tool N1.
• 790-201-1861 1
5 (For boom)
• Push tool
• 790-201-1871 1
(For arm)
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• Plate
6 • 790-201-1660 (For bucket)
1
• Plate
• 790-201-1670 1
(For boom)
• Plate
• 790-201-1680 1 ii) Remove piston assembly lock screw (3).
(For arm)
a This work is common to the boom,
arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75
PC400, 450-7E0 23
a If screw (3) is so caulked that you iv) Remove plunger (5).

cannot remove it, tighten it tempo- q Perform this work for only the
rarily and tap the threads on it, and boom and arm cylinder.
then remove it. v) Remove collar (6).
q Perform this work for only the
boom and arm cylinder.
vi) Remove head assembly (7).
iii) Using tool N2, remove piston assem-

bly (4).
q When not using tool N2, loosen
the piston assembly by using the vii) Remove cap (8), 11 balls (9), and
drilled holes (Ø10: 2 places) (in plunger (10).
which the pins of N2 are inserted q Perform this work for only the
in the following figure). arm cylinder.
a Since cap (8) is made of nylon,
tighten a screw into it and pull it
with pliers.
24 PC400, 450-7E0
2. Disassembly of piston assembly Assembly

1) Remove rings (11). a Take care not to damage the packings, dust
2) Remove wear rings (12). seals, O-rings, etc.
3) Remove piston ring (13). a Clean the all parts. After installing them, cover
4) Remove the O-ring and backup rings (14). the piping ports and pin holes to prevent dirt
from entering.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60°C and then insert it.
3. 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). 1. Assembly of cylinder head assembly
4) Remove buffer ring (19). 1) Using tool N5, press fit bushing (20).
5) Remove snap ring (21). 2) Install buffer ring (19).
6) Remove bushing (20). 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 25
2. Assembly of piston assembly 3. Piston rod assembly

1) Using tool N3, expand piston ring (13). 1) Set the piston rod to tool N1.
a Set piston ring (13) to tool N3 and 2) Install cylinder head assembly (7) to the
t ur n th e h an d le 8 – 1 0 t im e s t o piston rod.
expand the piston ring. 3) Fit the O-ring and backup ring to collar (6),
2) Set tool N4 and contract piston ring (13). 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.
3) Install backup ring and O-ring (14).

4) Install wear ring (12).
5) Install ring (11).
a Do not increase the closed gap of the
ring too much.
5) Set plunger (10) to the piston rod. Install
2 Ring groove: Grease (G2-LI) 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 cyl-
inder.
26 PC400, 450-7E0
6) Assemble piston assembly (4) according iii) Make a screw hole to install screw
to the following procedure. (3).
q When reusing the rod and piston a Apply a drill to the V-groove of
assembly (4) the threaded parts of piston (4)
i) Tighten piston assembly (4). Then, and rod (2) and make a hole.
using tool N2, tighten piston assem- a When making a hole on the cylin-
bly (4) until the screw holes are der (arm cylinder) having the bot-
aligned. tom cushion, make it around the
a Remove the burrs from the cushion plug.
threads with a file. q Dimensions of screw hole (mm)
Go to iv).
Tap drill diameter Tap to be used
10.3 12 x 1.75
Tap drill Tapping

hole depth depth
Bucket/
27 20
Boom
Arm 36 29
iv) Tighten screw (3).

a Clean the parts thoroughly and
remove metal chips, dirt, etc.
2
q When replacing either or both of Threads of screw:
the rod and piston assembly (4) Adhesive (LOCTITE No. 262)
3 Screw:
with new ones
a Make a mark of the cushion plug
58.9 – 73.6 Nm {6 – 7.5 kgm}
position on the end of the rod having
the bottom cushion. v) Caulk the threaded part [1] by 4 places
q Perform this work for only the arm cyl- with a punch.
inder.
ii) Using the tool, tighten piston assem-
bly (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 Perform this work for only the
boom and arm cylinders.
PC400, 450-7E0 27
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
Tightening torque
name
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}
9) Install the piping.
28 PC400, 450-7E0
PC400, 450-7E0 29
SEN03612-02

© 2008 KOMATSU
All Rights Reserved
30
SEN03613-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC400, 450-7E0 1
Removal and installation of work 4. Start the engine and retract the piston rod.
equipment assembly 1 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
Special tools that the cylinder will not lower. When put-
ting the wood block, remove the grease fit-
Necessity
ting on the bottom side.
Symbol
Sketch
Q’ty
N/R
Part number Part name a Disconnect the boom cylinder on the
opposite side similarly.
796-670-1100 Remover q 1 a When slinging the boom cylinder, if the
• 796-670-1110 Sleeve 1 sling interferes with the work equipment
lamp, remove the work equipment lamp.
• 796-670-1120 Plate 1
• 796-670-1130 Screw 1 5. Disconnect intermediate connector A42 (6) for
• 796-870-1110 Adapter 1 the work equipment lamp.
P • 01643-33080 Washer 1
6. Disconnect 3 arm cylinder hoses (7) and 2
• 01803-13034 Nut 1
bucket cylinder hoses (8).
790-101-4000
Puller
q 1 a Put oil stopper plugs and secure the
(490 kN {50t}, long) hoses to the valve side with ropes.
Pump
790-101-1102 q 1
(294 kN {30t})
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.
k See Testing and adjusting, “Releasing resid-
ual pressure from hydraulic circuit”.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2) temporarily

7. Sling work equipment assembly (12) tempo-
and remove lock bolt and nut (3). [*1]
rarily.
3. Remove plate (4) and head pin (5). [*2]
8. Remove cover (9), plate (10), and foot pin (11)
a Check the quantity and positions of the
to disconnect work equipment assembly (12).
inserted shims.
[*3]
2 PC400, 450-7E0
q When removing with tool P Installation

Remove plate (10). Sling and set tool P q Carry out installation in the reverse order to
and remove foot pin (11) to disconnect removal.
work equipment assembly (12).
a Check the quantity and positions of the [*1]
inserted shims. a Tighten the locknut so that clearance (a)
between the plate and nut will be 0.5 – 1.5 mm.
9. Move the machine in reverse to remove work

equipment assembly (12). [*2]
2
4 Work equipment assembly: Inside wall of bushing before assembling pin:
PC400-7E0, PC400LC-7E0: 7,400 kg Anti-friction composition (LM-P)
PC450-7E0, PC450LC-7E0: 8,400 kg 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
PC400, 450-7E0 3
[*3]
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 (c)
between boom (13) and bracket (14) will be 1
mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
q Bleeding air
various parts”.

again.
4 PC400, 450-7E0
PC400, 450-7E0 5
SEN03613-00

© 2008 KOMATSU
All Rights Reserved
6
SEN03614-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

Cab and its attachments
Removal and installation of operator’s cab ..................................................................................................... 2
Removal and installation of operator’s cab glass (stuck glass) ...................................................................... 5
Removal and installation of front window assembly ..................................................................................... 14
PC400, 450-7E0 1
Removal and installation of 4. Remove clip (10) and disconnect cab wiring
operator’s cab 1 connectors M45 (11), H08 (12), and H09 (13).
5. Remove air conditioner connector plate (14).

Removal
the battery.
1. Remove rear covers (1), (2), (3), and (4).
6. Disconnect connectors M71 (15), H10 (16),

H11 (17), and H12 (18).
7. Disconnect upper and lower duct joints (19)

and (20).
2. Remove duct (5), cover (6), and plate (7).
8. Remove controller sub-plate (21) and incline it
3. Remove plate (8), duct (9) and the element. against the air conditioner.
a Remove the duct lock clip.
9. Remove cover (22) and floor mat (23).
2 PC400, 450-7E0
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). 17. Take grommet (35) out of the right front of the
cab.
13. Remove ducts (27) and (28).
a Both (27) and (28) are 2 in number. 18. Disconnect the windshield washer hose from
a Cut the tie-wrap on the monitor wiring har- (36).
ness.
19. Remove 4 mounting bolts (37) and 5 mounting
14. Remove cover (29) and monitor assembly bolts (38).
(30). a Check the types of the bolts.
a In the initial period, 7 mounting bolts (38)
are used.
PC400, 450-7E0 3
20. Using lever block [1], lift off operator's cab Installation
assembly (39). q Carry out installation in the reverse order to
4 Operator's cab assembly: 300 kg 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
4 PC400, 450-7E0
Removal and installation of operator’s cab glass (stuck glass) 1
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 4 panes (1) – (4) (2) : Left side rear window glass
are stuck. (3) : Door lower window glass
In this section, the procedure for replacing the (4) : Front window glass
stuck glass is explained. (5) : Front window assembly
When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Both-sided adhesive tape
replace only the front window glass while the (16): Center trim seal
front window assembly is installed to the oper-
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see “Removal and installation
of front window assembly”.
PC400, 450-7E0 5
Special tools Installation

1. Using a knife and scraper, remove the remain-
Necessity
ing adhesive and both-sided adhesive tape
Symbol
Sketch
Q’ty
N/R
Part number Part name from the metal sheets (glass sticking surfaces)
of the operator's cab.
Lifter a Remove the adhesive and both-sided
1 793-498-1210 t 2
Y (Suction cup) adhesive tape to a degree that they will
2 20Y-54-13180 Adapter t 2 not affect adhesion of the new adhesive.
Take care not to scratch the painted sur-
f 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
Removal scratched, adhesion will be lowered.)
a Remove the window glass to be replaced
according to the following procedure. 2. Remove oil, dust, dirt, etc. from the sticking
surfaces of cab and window glass with white
1. Using seal cutter [1], cut the adhesive between gasoline.
broken window glass (7) and operator's cab a If the sticking surfaces are not cleaned
(metal sheet) (8). 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.
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. (Dis-
(The figure shows the operator's cab of a c a r d t h e p r i m e r 2 4 h o u r s a ft e r i t i s
wheel loader.) packed.)
a If a seal cutter is not available, widening 1) Stir the primers for paint and glass suffi-
the cut with a screwdriver, cut the adhe- ciently before using them.
sive and both-sided adhesive tape with a If the primer has been stored in a
knife [4]. refrigerator, leave it at the room tem-
perature 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. Accord-
ingly, 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.
2. Remove the window glass.
6 PC400, 450-7E0
a In addition to the above parts, apply

the primer to right side window glass
(1) and door lower window glass (3).
q Range to apply primer additionally for
right side window glass (1): (b)
q Range to apply primer additionally for
door lower window glass (3): (c)
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
3) Evenly apply paint primer to the surfaces

to stick both-sided adhesive tapes and the
surfaces out of those surfaces on opera-
tor'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 low-
ered.)
a Never apply wrong primer. If the glass

primer is applied by mistake, wipe it
off with white gasoline.
a Parts to be coated with primer: Apply
the primer all over dimension (a).
q Dimension to apply primer (a): 25 mm
PC400, 450-7E0 7
4) Evenly apply glass primer to the sticking 4. Stick both-sided adhesive tape (6) along the
surfaces of window glass (9). inside edge of the glass sticking section.
2 Glass primer: a Do not remove the release tape of the
SUNSTAR GLASS PRIMER both-sided adhesive tape on the glass
580 SUPER or equivalent sticking side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive
times. (If it is applied more than 2 tape, do not touch the cleaned surface as
times, its performance will be low- long as possible.
ered.) a Take that the both-sided adhesive tape will
not float at each corner of the window
frame.
a Parts to be coated with primer: Apply

the primer to the sticking surfaces of
window glass (9) and all over dimen- a When sticking both-sided adhesive tape
sion (d) which will be on both-sided (6) around a frame, do not lap its finishing
adhesive tape (6) and operator's cab end over the starting end but make clear-
(8). ance (e) of about 5 mm between them.
a Do not apply the primer to the 1) Stick both-sided adhesive tape (6) for right
boarder about 5 mm wide between side window glass (1) as shown in the fig-
the black part and transparent part of ure.
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply wrong primer. If the
glass primer is applied by mistake,
wipe it off with white gasoline.
8 PC400, 450-7E0
a Stick both-sided adhesive tape (6a) addi- a Stick both-sided adhesive tape (6b)
tionally for right side window glass (1). additionally for door lower window
q Positions to stick additional both-sided glass (3).
adhesive tape for right side window glass: a Positions to stick additional both-
(f) : 50 mm sided adhesive tape for door lower
(g) : 90 mm window glass:
(h) : 250 mm (j) : 110 mm
(k) : 90 mm
(m) : 200 mm
2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure. 4) Stick both-sided adhesive tape (6) for front
window glass (4) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the
figure.
PC400, 450-7E0 9
a 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 both-
sided adhesive tapes (6). (If it is stuck
along the inside, it will be seen
through the transparent part of the
glass.)
a When positioning front window glass

(4), set its horizontal position to the
frame width and set its vertical posi-
tion so that height difference (p)
between it and the frame top will be 3
mm.
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 position-
ing 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. 6. Apply adhesive.
3) Cut the tape between window glass (9) a Use either of the 2 types of the adhesive.
and operator's cab (8) with a knife, and 2 Adhesive (Summer):
then remove the window glass. SUNSTAR PENGUINE
a Do not remove the tapes left on the SEAL 580 SUPER "S"
window glass and operator's cab
2 Adhesive (Winter):
before installing the window glass.
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 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
10 PC400, 450-7E0
1) Break aluminum seal (13) of the outlet of 4) Remove the release tape of the both-
adhesive cartridge (12) and install the sided adhesive tape on the glass side.
nozzle. 5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab.
2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as fol-
lows. a Apply adhesive (15) to dimensions (s)
q Dimension (q): 10 mm and (t) of both-sided adhesive tape
q Dimension (r) : 15 mm (6) of operator's cab (8).
q Dimension (s): 10 mm
q Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
3) Set adhesive cartridge (12) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
PC400, 450-7E0 11
a 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.
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup Y1.
a After installing front window glass (4),

7. Install the window glass. fill the clearances between it and cen-
1) Install window glass (9), matching it to the ter trim seal (16) with caulking mate-
lines of the positioning tapes drawn in step rial in range (s) to dimensions (t) and
5. (u).
a Since the window glass cannot be After applying the primer to glass (4)
removed and stuck again, stick it very of section (A) – (A), apply adhesive
carefully. as caulking material.
a Stick the glass within 5 minutes after q Caulking dimension (t) : 2 mm
applying the adhesive. q Caulking dimension (u) : 5 mm
2) After sticking window glass (9), press all a When caulking, mask the glass side
around it until it is stuck to the both-sided and form the adhesive with a rubber
adhesive tape. spatula as shown in the figure.
a Press the corners of the window glass a Wipe off projected adhesive.
firmly. 2 Glass primer:
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
12 PC400, 450-7E0
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
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. 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 adhe-
sive 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 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
PC400, 450-7E0 13
Removal and installation of front 5. Release the rear locks.

window assembly 1
6. Lower the front window assembly carefully a
little. Put out rollers (8) and (9) under the both
k Lower the work equipment to the ground sides of the front window through the portion
and stop the engine. from which the corner blocks were removed in
a To replace the front window glass, the front step 3 (the portion where the rail is open) and
window assembly must be removed from the hold them.
operator's cab. The procedure for removing
and installing the front window assembly (front 7. Remove rollers (8) and (9) under the both
frame and front window glass) is explained sides of the front window.
below.
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.
14 PC400, 450-7E0
8. Remove left lower pin (10). [*3] 10. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) a Do not let the front window assembly
at the end of pull-up assist cable (11) touch the monitor.
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 discon-
nect pull-up assist cable (11).
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 win-
dow assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower
it gradually.
PC400, 450-7E0 15
Installation

removal.
[*1] [*2]
q Adjust opening and closing of the front window
assembly according to the following proce-
dure.
1. Open and close the front window to check that

it does not interfere with the rails and the roll-
ers 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}
16 PC400, 450-7E0
3. Raise the front window assembly and fix it with 5. Install left corner blocks (1) and (2) and secure
the rear locks (on both sides). left corner bracket (6) with left striker bolt (4).
a Check that the locks in the rear of the a Tighten the striker bolt securely after
operator's cab are applied securely. adjusting it in step 6.
a Install the left corner blocks so that there
4. Install right corner block (3) and fix right corner will be no level difference at 2 part (d).
block bracket (7) with right striker bolt (5). a Secure roller clearance (e).
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.
PC400, 450-7E0 17
6. Adjust the striker bolts according to the follow- 2) Open and close the front window assem-
ing procedure (Adjust the "CLOSE" positions bly and check the working condition of
of the front window assembly locks). both locks (20) and (21).
1) Tighten left striker bolt (4) and right striker i) If both locks do not work normally,
bolt (5) at roughly right positions so that move the striker bolts toward the rear
front window glass (18) will be fitted to of the cab and tighten them again.
cab-side trim seal (19). 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.
7. After adjusting the striker bolts, splash water

heavily over the front window glass and check
that the water does not leak into the cab.
18 PC400, 450-7E0
8. Adjust the "opening" lock of the front window 9. Adjust the front window stoppers.
assembly. 1) After adjusting "closing" lock of the front
1) After adjusting the "closing" lock of the window assembly in step 9, check the
front window in step 6, raise the front win- contact of both front window stoppers
dow assembly to the ceiling. (23).
2) Set the right and left front window assem- 2) If both stoppers (23) do not contact nor-
bly locks at the rear of the operator's cab mally, adjust and fix them at places where
to the "OPEN" positions, and then check they contact normally.
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 stop-
pers (24) are in contact with the front
window assembly and their deflec-
tion allowance is 1.5 – 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera-
tor's cab.
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 oper-
ator's cab) and "opening" side (in the
rear of the operator's cab).
[*3]
3 Left lower pin: 27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC400, 450-7E0 19
SEN03614-01

© 2008 KOMATSU
All Rights Reserved
20
SEN03615-02
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up

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 1
Removal and installation of air 4. Remove duct (5), cover (6), and plate (7).
conditioner unit assembly 1
5. Remove plate (8) and duct (9).
a Remove the duct lock clip.
Removal
k Disconnect the negative (–) terminal from 6. Remove ducts (10) and (11).
battery.
k Drain the coolant or 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.
1. Swing the upper structure by 90°.
2. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance.
a Ask professional traders for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere. 7. Disconnect connectors D01 (12), D02 (13),
C09 (14), R22 (15), R20 (16), and K19 (17).
k If refrigerant gas (R134a) gets in your
eyes, you may lose your sight. Accord- 8. Remove and sling controller (18).
ingly, put on protective goggles while
you are collecting the refrigerant 9. Remove plate (19).
(R134a) or filling the air conditioner cir-
cuit with the refrigerant (R134a). Col- 10. Disconnect air conditioner unit connectors M27
lecting and filling work must be (20) and M33 (21).
conducted by a qualified person.
q Quality of refrigerant: 950 ± 50 g
3. Remove rear covers (1), (2), (3), and (4).
2 PC400, 450-7E0
11. Remove the air conditioner unit undercover. Installation

a Part A q Carry out installation in the reverse order to
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.
12. Remove mounting bolt (24) and connector
(25). [*1] 3 Hose clamp (M6 bolt):
8 – 12 Nm {0.8 – 1.2 kgm}
13. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1] 3 Hose screw of M16 x 1.5:
a Put tags to the disconnected hoses and 12 – 15 Nm {1.2 – 1.5 kgm}
tubes to prevent a mistake when re-con-
necting them. 3 Hose screw of M22 x 1.5:
20 – 25 Nm {2.0 – 2.5 kgm}
3 Hose screw of M24 x 1.5:

30 – 35 Nm {3.0 – 3.5 kgm}
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Quantity of refrigerant: 950 ± 50 g
14. Remove the 7 mounting bolts and air condi-

tioner unit assembly (27).
PC400, 450-7E0 3
Removal and Installation of Installation

KOMTRAX terminal assembly 1 q Carry out installation in the reverse order to
removal.
Removal
battery.
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 remove

KOMTRAX terminal assembly (7).
4 PC400, 450-7E0
Removal and installation of Installation

monitor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
the battery.
1. Remove cover (1) and disconnect wiring con-

nector 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 connec-
tors P01, P02, and P70 before removing
the monitor assembly.
PC400, 450-7E0 5
Removal and installation of pump Installation

controller 1 q Carry out installation in the reverse order to
removal.
Removal
the battery.
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 con-

troller assembly (7).
6 PC400, 450-7E0
PC400, 450-7E0 7
SEN03615-02

© 2008 KOMATSU
All Rights Reserved
8
SEN03618-00
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC400, 450-7E0 1
SEN03618-00 90 Diagrams and drawings
2 PC400, 450-7E0
Hydraulic circuit diagram
Hydraulic circuit diagram PC400, 400LC-7E0, PC450, 450LC-7E0 1 PC400, 400LC-7E0, PC450, 450LC-7E0
SEN03618-00
PC400, 450-7E0 3
90 Diagrams and drawings SEN03618-00
PC400, 450-7E0 5
SEN03618-00

© 2008 KOMATSU
All Rights Reserved
6
SEN03617-01
PC400-7E0
PC400LC-7E0
PC450-7E0
PC450LC-7E0
PC400-7E0 60001 – 60089
65001 and up
PC400LC-7E0 60001 – 60089
65001 and up
PC450-7E0 30001 – 30058
65001 and up
PC450LC-7E0 30001 – 30058
65001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram...................................................................................................................... 13
PC400, 450-7E0 1
SEN03617-01 90 Diagrams and drawings
2 PC400, 450-7E0
Electrical circuit diagram (1/5)
Electrical circuit diagram (1/5) 1 PC400, 400LC-7E0, PC450, 450LC-7E0
SEN03617-01
PC400, 450-7E0 3
SEN03617-01
PC400, 450-7E0 5
SEN03617-01
PC400, 450-7E0 7
SEN03617-01
PC400, 450-7E0 9
SEN03617-01
PC400, 450-7E0 11
Connector list and stereogram
Connector list and stereogram PC400, 400LC-7E0, PC450, 450LC-7E0 PC400, 400LC-7, PC450, 450LC-7E0
Connector Number Address of Connector Number Address of

Model Component name Model Component name
No. of pins stereogram No. of pins stereogram
A01 X 4 Intermediate connecter V-1 P01 070 12 Monitor panel P-6
A02 X 4 Intermediate connecter W-1 P01 AMP 3 Bucket CURL pressure sensor L-2
A03 DT 12 Intermediate connecter Q-1 P02 040 20 Monitor panel P-5
A04 SWP 6 Intermediate connecter R-1 P02 X 2 Boom LOWER pressure switch L-2
A05 SWP 14 Intermediate connecter W-1 P03 X 2 Swing RIGHT pressure switch L-2
A06 SWP 14 Intermediate connecter Q-1 P04 AMP 3 Arm IN pressure sensor L-2
A07 SWP 16 Intermediate connecter V-1 P05 X 2 Bucket DUMP pressure switch L-1
A09 SWP 8 Intermediate connecter P-2 P06 X 2 Boom RIGHT pressure switch L-1
A13 DT 2 Intermediate connector (to boom working lamp) P-1 P07 X 2 Swing LEFT pressure switch L-1
A22 DT 2 Rear working lamp H-9 P08 X 2 Arm OUT pressure switch L-1
CE02 DRC 50 Engine controller AK-5 P09 X 2 Travel hydraulic pressure switch (Black) R-1
CE03 DRC 4 Engine controller AK-6 P10 X 2 Travel hydraulic pressure switch (Steering signal) (Red) R-1
CN1 DT 2 No. 1 fuel injector AK-9 P13 X 2 Intermediate connector K-3
CN2 DT 2 No. 2 fuel injector AK-9 P15 2 Air conditioner daylight sensor P-6
CN3 DT 2 No. 3 fuel injector AL-9 P16 X 2 Bottom dump close switch (Loading shovel spec.) L-4
CN4 DT 2 No. 4 fuel injector AN-7 P17 2 Air conditioner high-pressure switch W-9
CN5 DT 2 No. 5 fuel injector AN-7 P20 M 3 Fuel control dial R-8
CN6 DT 2 No. 6 fuel injector AN-7 P21 X 1 Fuel level sensor D-9
CP01 DRC 24 Pump controller Y-9 P22 D 2 Hydraulic oil temperature sensor K-3
CP02 OTP 40 Pump controller X-9 P23 D 2 Air cleaner clogging sensor G-9
CP03 DRC 40 Pump controller X-9 P24 X 2 Radiator coolant level sensor AJ-1
D01 SWP 8 Concentrated diode AB-2 P25 AMP 3 F pump oil pressure sensor L-4
D02 SWP 8 Concentrated diode AB-2 P26 AMP 3 R pump oil pressure sensor K-3
D10 2 Diode AA-8 P30 X 2 Bottom dump open switch (Loading shovel spec.) L-4
D11 2 Diode AA-8 P44 D 2 Engine oil level switch AK-5
EGR DT 2 EGR valve AJ-9 P70 040 16 Monitor panel P-4
ENG DRC 60 Engine controller AK-6 PAMB FRAMATOME 3 Atmospheric pressure sensor AM-9
F01 20 Fuse X-2 PFUEL AMP 3 Common rail pressure sensor AL-5
F02 M 2 Revolving warning lamp (if equipped) AB-9 PIM CANNON 3 Boost pressure sensor AN-6
F04 L 2 Fusible link (65A) B-6 POIL FRAMATOME 3 Engine oil pressure sensor AJ-6
F05 M 2 Fusible link (30A) E-2 PCV1 SUMITOMO 2 Fuel supply pump PCV1 AJ-6
G SUMITOMO 3 Engine G sensor AJ-6 PCV2 SUMITOMO 2 Fuel supply pump PCV2 AJ-6
G01 DRC 40 KOMTRAX Y-9 R01 Terminal 1 Battery relay (Terminal E) B-6
G02 M 1 (Male) for inspection Y-9 R02 Terminal 1 Battery relay (Terminal BR) B-7
G03 M 1 (Female) for inspection Y-9 R03A Terminal 1 Battery relay (Terminal M) D-6
G04 M 1 (Male) for inspection Z-9 R03B Terminal 1 Battery relay (Terminal M) D-6
G05 M 1 (Female) for inspection Z-9 R04 Terminal 1 Battery relay (Terminal B) D-7
H06 090 20 Intermediate connector (to right console upper wiring harness) Q-8 R05 Relay 5 Light relay S-8
H07 M 1 Chassis ground (Floor frame) W-2 R06 Relay 5 Starting motor cutout relay (PPC lock) S-9
H08 M 8 Intermediate connector (Speaker) AA-6 R07 Relay 5 Starting motor cutout relay (Personal code) T-9
H09 S 8 Intermediate connector (Light) AA-5 R08 Relay 6 Horn relay AB-1
H10 S 16 Intermediate connector (Monitor panel) W-9 R15 Terminal 1 Intake air heater relay (Inlet) C-5
H11 S 16 Intermediate connector (Monitor panel) V-9 R16 Terminal 1 Intake air heater relay (Outlet) D-5
H12 S 12 Intermediate connector (Monitor panel) V-9 R17 Terminal 1 Intake air heater relay (Drive coil inlet) B-6
J01 20 Joint connector (Black) Y-2 R18 Relay 5 Intake air heater relay (Drive relay) Z-2
J02 20 Joint connector (Black) Y-3 R20 Relay 5 ATT circuit selector relay Z-2
J03 20 Joint connector (Green) Y-3 R23 Relay 5 Engine power supply relay (1) Z-2
J04 20 Joint connector (Green) Z-3 R24 Relay 5 Engine power supply relay (2) Z-1
J05 20 Joint connector (Pink) Z-3 R30 SUMITOMO 5 Air conditioner blower relay AA-4
J06 20 Joint connector (Orange) Z-3 R31 AMP 4 Air conditioner compressor relay AA-7
J07 20 Joint connector (Orange) Z-3 RES DT 2 Resistance (620z) AN-8
J1939 DT 3 CAN connector AM-9 S01 Terminal 6 Starting switch R-8
JM01 9 Centralized terminals (Engine) AL-9 S02 M 3 Light switch S-8
JM02 12 Centralized terminals (Engine) AL-9 S04 M 4 Swing lock switch S-9
JM03 10 Centralized terminals (Engine) AN-8 S05 M 2 Machine push-up switch T-9
K01 M 2 Resistor (30z) Z-1 S07 M 2 Revolving warning lamp switch X-2
K02 DT 3 CAN terminal resistance AJ-6 S10 090 2 Horn switch R-8
K31 D 3 CAN terminal resistance P-4 S10 X 2 Pressure switch for service switch (Front) (if equipped) J-3
L01 4 Working lamp (Right front) E-9 S11 090 2 Knob switch (Left) W-1
L02 D 2 Working lamp (if equipped) C-2 S11 X 2 Pressure switch for service switch (Rear) (if equipped) K-3
L09 D 2 Working lamp (Boom) J-9 S14 M 2 PPC oil pressure lock switch V-1
M01 PA 9 Radio W-2 S21 Terminal 6 Emergency pump drive switch U-9
M06 KES 2 Windshield washer motor L-4 S22 Terminal 6 Swing holding brake release switch T-9
M07 090 2 Horn (High tone) F-1 S25 090 16 Intermediate connector (to right console emergency switch) U-9
M08 090 2 Horn (Low tone) E-1 S30 S 8 Model selection connector Z-2
M09 M 2 Optional power supply AA-4 S41 DT 2 Switch box (Fuel priming pump) (if equipped)
M10 M 2 Optional power supply AA-6 SEGR DT 4 EGR valve position sensor AJ-9
M11 M 3 DC/DC converter AA-6 T01 Terminal 1 Floor frame ground Y-3
M12 M 2 Service connector AA-7 T03 Terminal 1 Radio body ground V-9
M13 M 2 Speaker (Right) AG-8 T04 Terminal 1 Revolving frame ground H-1
M14 D 2 Travel alarm J-2 T05 Terminal 1 Revolving frame ground H-1
M17 D 2 Starting motor (S/R terminal circuit) AI-1 T06 Terminal 1 Revolving frame ground I-2
M18 Terminal 1 Alternator R terminal AK-1 T07 Terminal 1 Revolving frame ground I-2
M19 2 Cigarette lighter P-3 T08 Terminal 1 Revolving frame ground D-2
M20 Terminal 1 Starting motor B terminal AI-1 T09 Terminal 1 Revolving frame ground I-2
M21 Terminal 1 Alternator B terminal AL-1 T10 Terminal 1 Revolving frame ground J-2
M22 Terminal 1 Alternator E terminal AK-1 T11 Terminal 1 CAB ground AH-3
M23 Terminal 1 Intake air heater AK-9 T11 Terminal 1 Engine body ground AL-5
M24 D 2 Fuel priming pump (if equipped) T12 Terminal 1 Alternator ground AJ-1
M25 D 2 Fuel priming pump (if equipped) F-9 TFUEL PACKARD 2 Fuel temperature sensor AL-5
M26 S 12 Air conditioner harness AA-4 TIM PACKARD 2 Boost temperature sensor AM-9
M27 18 Air conditioner unit AA-5 TWTR PACKARD 3 Coolant temperature sensor AJ-1
M29 20 Air conditioner control unit X-2 V01 DT 2 PPC oil pressure lock solenoid valve M-5
M30 16 Air conditioner control unit X-2 V02 DT 2 Travel junction solenoid valve M-5
M33 4 Air conditioner unit AA-5 V03 DT 2 Merge-divider solenoid valve M-5
M33 M 2 Optional power supply V04 DT 2 Travel speed solenoid valve (Hi/Lo) M-5
M34 X 1 Air conditioner compressor electromagnetic clutch H-9 V05 DT 2 Swing holding brake solenoid valve M-4
M40 M 2 Light switch (if equipped) AD-8 V06 DT 2 Machine push-up solenoid valve M-4
M41 M 2 Light switch (if equipped) AC-7 V07 DT 2 ATT return selector solenoid valve (if equipped) M-3
M45 DT 12 Network bus AA-7 V08 DT 2 2-stage relief solenoid valve M-4
M71 M 2 Room lamp AD-8 V11 DT 2 PC-EPC solenoid valve L-6
M72 M 4 DC/DC converter V19 DT 2 LS-EPC solenoid valve L-7
M73 M 2 Speaker (Left) AH-8 V20 DT 2 Bottom dump close solenoid valve (Loading shovel spec.) L-4
M79 M 2 12V outlet Z-8 V21 DT 2 Bottom dump open solenoid valve (Loading shovel spec.) L-4
M81 X 2 Bucket quick coupler control box (if equipped) V30 X 2 ATT flow adjustment EPC solenoid valve (if equipped) S-1
M81 X 2 Bucket quick coupler solenoid (if equipped) W03 M 2 Rear limit switch AF-9
N01 M 4 Y-9 W04 M 6 Wiper motor AC-4
NE FRAMATOME 3 Engine NE sensor AL-5
SEN03617-01
PC400, 450-7E0 13
90 Diagrams and drawings SEN03617-01
PC400, 450-7E0 15
SEN03617-01

© 2008 KOMATSU
All Rights Reserved
16

PC400-7EO PC450-7EO Série 65001 e Acima

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PC400-7EO PC450-7EO Série 65001 e Acima

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SEN03578-03

HYDRAULIC PC400 -7E0

HYDRAULIC EXCAVATOR 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword ......................................................................................................... SEN03579-03

10 Structure, function and maintenance standard ............................................................... SEN03584-02

20 Standard value table ....................................................................................................... SEN03594-02

30 Testing and adjusting ...................................................................................................... SEN03596-02

40 Troubleshooting .............................................................................................................. SEN03599-02

Troubleshooting of engine (S-mode) .............................................................................. SEN03606-01

50 Disassembly and assembly ............................................................................................ SEN03607-03

90 Diagrams and drawings .................................................................................................. SEN03616-01

10 Structure, function and maintenance standard

Hydraulic system, Part 3................................................................................................. SEN03590-00

20 Standard value table

30 Testing and adjusting

Measuring PPC valve output pressure .................................................................................... 47

Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 51

Failure code [DW91KB] Travel Junction Sol. Short Circuit ...................................................... 32

50 Disassembly and assembly

Removal and installation of radiator assembly ........................................................................ 29

90 Diagrams and drawings

PC400, 450(LC)-7E0 Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.