PC450 8

SEN04239-08
HYDRAULIC PC400 -8R

EXCAVATOR
PC400LC -8R
PC450 -8R
PC450LC -8R
PC400- 75001
PC400LC- 75001
SERIAL NUMBERS and up
PC450- 75001
PC450LC- 75001
SEN04241-08
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
Machine model Serial number

PC400-8R 75001 and up
PC400LC-8R 75001 and up
PC450-8R 75001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC400, 450-8R 1
SEN04241-08 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 SEN04239-08
00 Index and foreword SEN04240-08

Index SEN04241-08 q
Foreword and general information SEN04242-00
01 Specification SEN04243-02
Specification and technical data SEN04244-02
10 Structure, function and maintenance standard SEN04245-05

Engine and cooling system SEN04246-00
Power train SEN04247-00
Undercarriage and frame SEN04248-00
Hydraulic system, Part 1 SEN04249-00
Work equipment SEN04252-00
Cab and its attachments SEN04253-00
Electrical system SEN04254-02
20 Standard value table SEN04255-01

Standard service value table SEN04256-01
30 Testing and adjusting SEN04257-05

Testing and adjusting, Part 1 SEN04258-03
40 Troubleshooting SEN04261-02
Failure code table and fuse locations SEN04262-01
General information on troubleshooting SEN04263-01
Troubleshooting by failure code (Display of code), Part 1 SEN04264-02
Troubleshooting of electrical system (E-mode) SEN04267-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN04268-01
2 PC400, 450-8R
Troubleshooting of engine (S-mode) SEN04269-01
50 Disassembly and assembly SEN04270-05

General information on disassembly and assembly SEN04271-01
Undercarriage and frame SEN04274-03 q
Hydraulic system SEN04275-01
90 Diagrams and drawings SEN04279-01

Hydraulic diagrams and drawings SEN04280-00
Electrical diagrams and drawings SEN04281-01 q
PC400, 450-8R 3
Table of contents 1
00 Index and foreword
Index SEN04241-08
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN04242-00

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of connectors newly used for engines.......................................................................... 20
Handling of electric equipment and hydraulic component........................................................... 11
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 SEN04244-02
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 12
10 Structure, function and maintenance standard

Engine related parts .................................................................................................................... 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train .................................................................................................................................. 2
Swing circle ................................................................................................................................. 3
Swing machinery ......................................................................................................................... 4
Final drive.................................................................................................................................... 6
Sprocket ...................................................................................................................................... 8
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 ........................................................................................................................................... 14
Functions and operation by valve................................................................................................ 18
Merge-divider valve ..................................................................................................................... 33
Attachment circuit selector valve ................................................................................................. 58
Holding valve............................................................................................................................... 60
4 PC400, 450-8R

Valve control................................................................................................................................ 2
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 ......................................................................................................... 4
Air conditioner piping................................................................................................................... 2
Engine control ............................................................................................................................. 2
Electronic control system ............................................................................................................ 12
Monitor system............................................................................................................................ 37
Sensors ....................................................................................................................................... 64
KOMTRAX system ...................................................................................................................... 67
20 Standard value table

Standard service value table SEN04256-01
Standard value table for engine related parts.............................................................................. 2
Standard value table for chassis related parts ............................................................................ 3
30 Testing and adjusting

Tools for testing, adjusting and troubleshooting .......................................................................... 3
Sketches of special tools............................................................................................................. 7
Measuring engine speed............................................................................................................. 8
Measuring air boost pressure...................................................................................................... 9
Measuring exhaust gas temperature........................................................................................... 10
Measuring exhaust gas color ...................................................................................................... 11
Adjusting valve clearance ........................................................................................................... 12
Measuring compression pressure ............................................................................................... 14
Measuring blow-by pressure ....................................................................................................... 16
Testing engine oil 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........................................................................................................ 23
Checking fuel circuit for leakage ................................................................................................. 27
Checking and adjusting fan belt and alternator belt .................................................................... 28
Checking and adjusting air conditioner compressor belt tension ................................................ 29
Measuring swing circle bearing clearance .................................................................................. 30
Checking and adjusting track shoe tension................................................................................. 31
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................. 32
Measuring control circuit basic pressure..................................................................................... 36
Checking and adjusting pump PC control circuit oil pressure ..................................................... 37
Checking and adjusting pump LS control circuit oil pressure...................................................... 40
Measuring solenoid valve output pressure.................................................................................. 45
Measuring PPC valve output pressure........................................................................................ 48
Adjusting play of work equipment and swing PPC valves........................................................... 49
PC400, 450-8R 5
Inspecting locations of hydraulic drift of work equipment ............................................................ 50

Releasing residual pressure from hydraulic circuit...................................................................... 52
Measuring oil leakage amount .................................................................................................... 53
Bleeding air from various parts.................................................................................................... 56
Special functions of machine monitor.......................................................................................... 2
Handling voltage circuit of engine controller................................................................................ 2
Preparation work for troubleshooting of electrical system ........................................................... 3
Procedure for testing diodes ....................................................................................................... 8
Pm Clinic service......................................................................................................................... 9
40 Troubleshooting
Failure code table and fuse locations SEN04262-01
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 5
General information on troubleshooting SEN04263-01
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] Air cleaner 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 Level Low ........................................................................... 14
Failure code [B@HANS] Hydr Oil Overheat................................................................................ 16
Failure code [CA111] EMC Critical Internal Failure ..................................................................... 17
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 17
Failure code [CA122] Chg Air Press Sensor High Error.............................................................. 18
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 20
Failure code [CA131] Throttle Sensor High Error........................................................................ 22
Failure code [CA132] Throttle Sensor Low Error ........................................................................ 24
Failure code [CA135] Eng Oil Press Sensor High Error.............................................................. 26
Failure code [CA141] Eng Oil Press Sensor Low Error............................................................... 28
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 .................................................................. 44
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 ..................................................................................... 56
Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 58
6 PC400, 450-8R

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..................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 28
Failure code [CA757] All Persistent Data Lost Error ................................................................... 30
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 32
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 34
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 36
Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................... 37
Failure code [CA2249] Rail Press Very Low Error ...................................................................... 38
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................ 40
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................. 42
Failure code [D110KB] Battery Relay Drive S/C ......................................................................... 44
Failure code [D196KA] Service Return Relay Disc. .................................................................... 46
Failure code [D196KB] Service Return Relay S/C ...................................................................... 48
Failure code [DA25KP] 5V sensor power supply output 1 abnormality....................................... 50
Failure code [DA2SKQ] Model Selection Abnormality ................................................................ 53
Failure code [DA2RMC] CAN discon (Pump con detected) ........................................................ 4
Failure code [DAFRMC] CAN discon (Monitor detected) ............................................................ 6
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................... 8
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................... 10
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality .......................................................... 12
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ........................................ 14
Failure code [DW43KA] Travel Speed Sol. Disc. ........................................................................ 16
Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................... 18
Failure code [DW45KA] Swing Brake Sol. Disc. ......................................................................... 20
Failure code [DW45KB] Swing Brake Sol. S/C ........................................................................... 24
Failure code [DW91KA] Travel Junction Sol. Disc. ..................................................................... 26
Failure code [DW91KB] Travel Junction Sol. S/C ....................................................................... 28
Failure code [DWA2KA] Attachment Sol Open Circuit ................................................................ 30
Failure code [DWJ0KA] Merge-divider Sol. Disc......................................................................... 31
Failure code [DWJ0KB] Merge-divider Sol. S/C.......................................................................... 33
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ....................................................................... 35
Failure code [DWK0KB] 2-stage Relief Sol. S/C ......................................................................... 37
Failure code [DXA0KA] PC-EPC Sol. Disc. ................................................................................ 39
Failure code [DXA0KB] PC-EPC Sol. S/C .................................................................................. 41
Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................. 43
Failure code [DXE0KB] LS-EPC Sol. S/C ................................................................................... 45
Failure code [DXE4KA] Service Current EPC Disc..................................................................... 47
Failure code [DXE4KB] Service Current EPC S/C...................................................................... 48
Failure code [DY20KA] Wiper Working Abnormality ................................................................... 49
PC400, 450-8R 7
Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 51

Failure code [DY2CKB] Washer Drive Short ............................................................................... 53
Failure code [DY2DKB] Wiper Drive (For) Short ......................................................................... 55
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................ 57
Troubleshooting of electrical system (E-mode) SEN04267-01
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 system 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 indicate 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 and window washer do 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 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
E-32 Electric priming pump does not operate or does not stop automatically ............................ 66
Troubleshooting of hydraulic and mechanical system (H-mode) SEN04268-01
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
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
8 PC400, 450-8R
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) SEN04269-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN04271-01
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tools list........................................................................................................................... 7
Sketches of special tools............................................................................................................. 10
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 .............................................................................. 13
Removal and installation of cylinder head assembly .................................................................. 16
Removal and installation of radiator assembly............................................................................ 25
Removal and installation of hydraulic oil cooler assembly .......................................................... 27
Removal and installation of aftercooler assembly ....................................................................... 29
Removal and installation of engine and hydraulic oil pump assembly ........................................ 30
Removal and installation of final drive assembly ........................................................................ 2
Disassembly and assembly of final drive assembly .................................................................... 3
Removal and installation of swing motor and swing machinery assembly.................................. 11
Disassembly and assembly of swing motor and swing machinery assembly ............................. 12
Removal and installation of swing circle assembly ..................................................................... 19
PC400, 450-8R 9

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 SEN04275-01
Removal and installation of center swivel joint assembly............................................................ 2
Disassembly and assembly of center swivel joint assembly ....................................................... 4
Removal and installation of hydraulic tank assembly .................................................................. 5
Removal and installation of control valve assembly .................................................................... 7
Disassembly and assembly of control valve assembly ............................................................... 10
Removal and installation of hydraulic pump assembly................................................................ 12
Removal and installation of oil seal in hydraulic pump input shaft .............................................. 15
Disassembly and assembly of work equipment PPC valve assembly ........................................ 16
Disassembly and assembly of travel PPC valve assembly ......................................................... 17
Disassembly and assembly of hydraulic cylinder assembly........................................................ 18
Removal and installation of work equipment assembly............................................................... 2
Removal and installation of operator cab assembly .................................................................... 2
Removal and installation of operator cab glass (stuck glass) ..................................................... 5
Removal and installation of front window assembly .................................................................... 15
Removal and installation of floor frame assembly ....................................................................... 22
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of KOMTRAX communication modem assembly ................................ 5
Removal and installation of monitor assembly ............................................................................ 6
Removal and installation of pump controller assembly ............................................................... 8
Removal and installation of engine controller.............................................................................. 10
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN04280-00
Hydraulic circuit diagram ............................................................................................................. 3
Electrical diagrams and drawings SEN04281-01
Electrical circuit diagram ............................................................................................................. 3
Connector arrangement diagram ................................................................................................ 13
10 PC400, 450-8R
PC400, 450-8R 11
SEN04241-08
PC400, 450(LC)-8R Hydraulic excavator

Form No. SEN04241-08
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
12
SEN04242-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 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, 450-8R 1
Safety notice 1 (Rev. 2007/03)

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 elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 PC400, 450-8R
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
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 cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot 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
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC400, 450-8R 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 seen well
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, 450-8R
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
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
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, 450-8R 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
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,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

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

installation in each section of "Disassembly
and assembly".
6 PC400, 450-8R
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, 450-8R 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, 450-8R
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
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, 450-8R 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

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 must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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
oil and water from the com-
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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 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, 450-8R
3. Push lock type

q 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 engine

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

(4) in the direction of the arrow.
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, 450-8R 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(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, 450-8R
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-
tor tric appliance General wiring
wire for AV
(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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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. (When using
torque wrench)
a The following table corresponds 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 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
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 corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 PC400, 450-8R
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, 450-8R 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 diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
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 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 — —
7. 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
34 PC400, 450-8R
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
PC400, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
PC400, 450-8R 41
SEN04242-00

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 01-08 (01)
42
SEN04244-02
PC400, 450-8R
SEN04244-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
01 Specification
Specification and technical data
Specification dimension drawings ............................................................................................................... 2

Specifications .............................................................................................................................................. 4
Weight table ................................................................................................................................................ 8
Table of fuel, coolant and lubricants............................................................................................................ 12
PC400, 450-8R 1
SEN04244-02 01 Specification
Specification dimension drawings

Dimensions
Item Unit PC400-8R PC400LC-8R PC450-8R PC450LC-8R
A Overall length mm 11,940 11,940 12,040 12,040

B Overall height mm 3,600 3,600 3,625 3,625
C Overall width mm 3,340 3,590 3,490 3,490
D Track shoe width mm 600 700 600 600
E Height of machine cab mm 3,250 3,250 3,250 3,250
F Tail swing radius mm 3,645 3,645 3,645 3,645
G Track overall length mm 5,055 5,385 5,055 5,385
Length of track on
H mm 4,382 4,712 4,382 4,712
ground
J Max. ground clearance mm 685 685 685 685
2 PC400, 450-8R
Working ranges
Working range Unit PC400-8R PC400LC-8R PC450-8R PC450LC-8R
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, 450-8R 3
Specifications
PC400-8R, PC400LC-8R
Machine model PC400-8R PC400LC-8R
Serial number 75001 and up
Bucket capacity m3 1.9 1.9
Weight of machine kg 42,740 43,640
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 (standard shoe) kPa {kg/cm2} 79.4 {0.81} 64.7 {0.66}
Overall length mm 11,940 11,940
Overall width mm 3,490 3,590
Overall width of track mm 2,990 3,090
Overall width of track when extended mm 3,490 3,590
Overall height mm 3,600 3,600
Ground clearance of upper structure mm 1,320 1,320
Dimensions
Min. ground clearance mm 685 685

Tail swing radius mm 3,645 3,645
Min. swing radius of work equipment mm 4,735 4,735
Height of work equipment at min.
mm 9,210 9,210
swing radius
Length of track on ground mm 4,382 4,712
Track gauge mm 4,020 4,350
Height of machine cab mm 3,250 3,250
Width of standard shoe mm 600 700
4 PC400, 450-8R

Model SAA6D125E-5
4-cycle, water-cooled, in-line, vertical, direct injection, with turbo-
Type
charger 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
Nm/rpm
Max. torque {kgm/rpm}
1,383/1,400 {141/1,400}
Engine
Max. speed at no load rpm 1,930

Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HPh} 208 {155}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 50 A
Battery 12 V, 110 Ah × 2
Radiator core type Aluminum wave type, 4 rows
Undercarriage
Carrier roller 2 on each side

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
Hydraulic motor Control valve Hydraulic pump
Type × No. HPV160+160 (190), variable displacement, piston type × 2

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
(with brake valve, parking brake): × 2
KMF230ABE-5, Fixed displacement piston type
Hydraulic system
Swing motor (with safety valve, holding brake, reverse rotation preventive
valve): × 1
Boom (*1) Arm (*1), (*2) Bucket
Double-acting pis- Double-acting pis- Double-acting pis-
Type
ton ton ton
Hydraulic cylinder
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, 450-8R 5
Serial Number 75001 and up
Bucket capacity m3 1.9 1.9
Operating weight kg 44,320 45,220
Max. digging depth mm 7,790 7,790
Working ranges
Max. vertical wall depth mm 6,600 6,600

Max. digging reach mm 12,005 12,005
Max. reach at ground level mm 11,800 11,800
Max. digging height mm 10,925 10,925
Performance
Max. dumping height mm 7,625 7,625

Max. digging force 258.9 {26,400} 258.9 {26,400}
kN {kg}
(using power max. function) (275.5 {28,300}) (275.5 {28,300})
Swing speed rpm 9.1 9.1
Swing max. slope angle deg. 17 17
Travel speed km/h Lo: 3.0, Mi: 4.2, Hi: 5.5 Lo: 3.0, Mi: 4.2, Hi: 5.5
Gradeability deg. 35 35
Ground pressure
(standard shoe) kPa {kg/cm2} 82.9 {0.85} 78.1 {0.80}
Overall length mm 12,040 12,040

Overall width mm 3,490 3,490
Overall width of track mm 2,990 2,990
Overall width of track when extended mm 3,490 3,490
Overall height mm 3,625 3,625
Ground clearance of upper structure mm 1,320 1,320
Dimensions
Min. ground clearance mm 685 685

Tail swing radius mm 3,645 3,645
Min. swing radius of work equipment mm 4,805 4,805
Height of work equipment at min.
mm 9,230 9,230
swing radius
Length of track on ground mm 4,382 4,712
Track gauge mm 4,020 4,350
Height of machine cab mm 3,250 3,250
Width of standard shoe mm 600 600
6 PC400, 450-8R

Model SAA6D125E-5
4-cycle, water-cooled, in-line, vertical, direct injection, with turbo-
Type
charger and aftercooler
No. of cylinders – bore × stroke mm 6 – 125 × 150
Piston displacement l {cc} 11.045 {11,045}
kW/rpm
Flywheel horsepower 257/1,900 {345/1,900}
{HP/rpm}
Nm/rpm
Performance
Max. torque 1,383/1,400 {141/1,400}

{kgm/rpm}
Engine
Max. speed at no load rpm 1,930

Min. speed at no load rpm 1,000
g/kWh
Min. fuel consumption 208 {155}
{g/HPh}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 50 A
Battery 12 V, 110 Ah × 2
Radiator core type Aluminum wave type, 4 rows
Undercarriage
Carrier roller 2 on each side

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
Hydraulic motor Control valve Hydraulic pump
Type × No. HPV160+160(190), ariable displacement, piston type × 2

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
(with brake valve, parking brake): × 2
KMF230ABE-5, Fixed displacement piston type
Hydraulic system
Swing motor (with safety valve, holding brake, reverse rotation preventive
valve): × 1
Boom (*1) Arm (*1), (*2) Bucket
Double-acting pis- Double-acting pis- Double-acting pis-
Type
ton ton ton
Hydraulic cylinder
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
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, 450-8R 7
Weight table
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Engine assembly 1,660 1,660
q Engine 1,314 1,314
q Damper 14.7 14.7
q Hydraulic pump 210 210
Radiator, oil cooler assembly 213 213
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,297 3,297
Operator's cab 570 570
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
Track frame assembly 11,367 11,934
Track frame 6,766 7,096
q Center frame 3,229 3,229
q 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
Track shoe assembly
q Standard triple grouser shoe (600 mm) 4,470 4,760
q Standard triple grouser shoe (700 mm) 4,890 5,210
q Wide triple grouser shoe (800 mm) 5,320 5,670
q Wide triple grouser shoe (900 mm) — 6,130
8 PC400, 450-8R
Unit: kg
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, 450-8R 9
Unit: kg
Engine assembly 1,660 1,660

q Engine 1,314 1,314
q Damper 14.7 14.7
q Hydraulic pump 210 210
Radiator oil cooler assembly 213 213
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,402 3,402
Operator’s cab 570 570
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
Track frame assembly 11,697 12,244
Track frame 6,766 7,096
q Center frame 3,229 3,729
q 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
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) — —
10 PC400, 450-8R
Unit: kg
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, 450-8R 11
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
12 PC400, 450-8R
Unit: l
PC400/400LC-8R, PC450/450LC-8R
Reservoir
Specified Refill
Engine oil pan 46 37
Swing machinery case 20 20
Final drive case
10.5 10.5
(each side)
Damper case 1.07 —
Hydraulic system 472 248
Fuel tank 650 —
Cooling system 36 —
a For the HO46-HM, use the oil recommended by Komatsu.
PC400, 450-8R 13
©2011 KOMATSU
All Rights Reserved
14
SEN04246-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine related parts ........................................................................................................................................ 2
Radiator, oil cooler and aftercooler ................................................................................................................. 3
PC400, 450-8R 1
SEN04246-00 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, 450-8R
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, 450-8R 3
SEN04246-00

© 2008 KOMATSU
All Rights Reserved
4
SEN04247-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Power train
Power train...................................................................................................................................................... 2
Swing circle..................................................................................................................................................... 3
Swing machinery............................................................................................................................................. 4
Final drive ....................................................................................................................................................... 6
Sprocket .......................................................................................................................................................... 8
PC400, 450-8R 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, 450-8R
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
No. Check Item Criteria Remedy
Axial clearance of bearing Standard clearance Repair limit
4 (when mounted on chassis) Replace
0.5 – 1.6 3.2
PC400, 450-8R 3
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 valve
7. No. 1 sun gear
4 PC400, 450-8R
1
Specifications
Reduction ratio:
19 + 68 × 16 + 68 = 24.039
19 16
Unit: mm
No. Check item Criteria Remedy
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
15 and No. 1 planetary gear
0.15 – 0.51 1.00
Backlash between No. 1 planetary

16 gear and ring gear 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

18 and No. 2 planetary gear 0.16 – 0.55 1.00

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, 450-8R 5
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
6 PC400, 450-8R
Unit: mm
Backlash between No. 1 sun gear Standard clearance Clearance limit
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


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, 450-8R 7
Sprocket 1
Unit: mm
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)
8 PC400, 450-8R
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, 450-8R 9
SEN04247-00

© 2008 KOMATSU
All Rights Reserved
10
SEN04248-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

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

a The following drawing indicates PC400LC-8R and PC450LC-8R.
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
6. Track shoe Model Q'ty (one side)
7. Center guard PC400, 450-8R 7
8. Front guard PC400LC-8R,
8
PC450LC-8R
2 PC400, 450-8R
Standard shoe
Models
PC400-8R PC400LC-8R PC450-8R PC450LC-8R
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
Track +3
Vertical width of idler 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, 450-8R 3
Idler 1
4 PC400, 450-8R
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
+0.087 –0.027
102.6 0.010 – 0.149
+0.037 –0.062
PC400, 450-8R 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, 450-8R
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 50.2 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 34.4 —
7 flange
Double flange 34.4 —
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 —
–0.350 +0.029 Replace bushing
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
11 bushing +0.087 +0.022
87.6 0.015 – 0.100 —
+0.037 –0.013
PC400, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
PC400, 450-8R 11
SEN04248-00

© 2008 KOMATSU
All Rights Reserved
12
SEN04249-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Hydraulic system, Part 1
Hydraulic equipment layout drawing ............................................................................................................... 2
Hydraulic tank and filter .................................................................................................................................. 4
Hydraulic pump ............................................................................................................................................... 6
PC400, 450-8R 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, 450-8R
PC400, 450-8R 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}
Bypass valve
Set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
4 PC400, 450-8R
PC400, 450-8R 5
Hydraulic pump 1
Type: HPV160+160 (190)
6 PC400, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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.
th e axia l d ir ection of cylinde r bloc 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, 450-8R
Control of pump delivery

q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump delivery (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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
PC400, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
(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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 29
SEN04249-00

© 2008 KOMATSU
All Rights Reserved
30
SEN04250-03
PC400, 450-8R
SEN04250-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up

maintenance standard
Control valve ............................................................................................................................................... 2

CLSS........................................................................................................................................................... 14
Functions and operation by valve ............................................................................................................... 18
Merge-divider valve..................................................................................................................................... 33
Attachment circuit selector valve ................................................................................................................ 58
Holding valve .............................................................................................................................................. 60
PC400, 450-8R 1
Control valve
Outline
q The control valve consists of a 7-spool valve (6- q Since all the valves are assembled together with
spool valve + boom Hi, arm Hi valve) and a set connecting bolts and their passes are connected
of service valves. A merge-divider valve, a back to each other inside the assembly, the assembly
pressure valve, a boom drift preventive valve are is compact and easy to maintain.
installed to it.
A1: To bucket cylinder bottom PR: To solenoid valve, PPC valve, and EPC valve
A2: To L.H. travel motor PS: From merge-divide solenoid valve
A3: To boom cylinder bottom PST: From travel junction valve solenoid valve
A4: To swing motor PX1: From 2-stage relief solenoid valve
A5: To R.H. travel motor PX2: From 2-stage relief solenoid valve
A6: To arm cylinder head T: To tank
A-1: To boom cylinder bottom T1: To tank
A-2: To attachment 1 TS: To tank
A-3: To attachment 2 TSW: To swing motor S-port (suction side)
B1: To bucket cylinder head
B2: To L.H. travel motor 1. 6-spool valve
B3: 2. Cover A
B4: To swing motor 3. Cover B
B5: To R.H. travel motor 4. Boom Hi and arm Hi valve
B6: To arm cylinder bottom 5. Service valve 1
B-1: To arm cylinder bottom 6. Service valve 2
B-2: To attachment 1 7. Merge-divider valve
B-3: To attachment 2 8. Boom drift preventive valve
BP1: Boom raising PPC output pressure 9. Quick return valve
BP5: From 2-stage safety valve solenoid valve 10. Boom Hi valve check 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
P7: From swing PPC and EPC valves
P8: From swing PPC and EPC valves
P9: From R.H. travel PPC valve
P10: From R.H. travel PPC valve
P11: From arm PPC and EPC valves
P12: From arm PPC and EPC valves
P-3: From service 1 and 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
2 PC400, 450-8R
General view
PC400, 450-8R 3
Sectional view
(1/5)
4 PC400, 450-8R
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 (Service 1)
9. Variable pressure compensation valve (Service 2)
10. Pressure compensation valve (Arm Hi in)
11. Pressure compensation valve (Bucket curl)
12. Pressure compensation valve (L.H. travel forward)
13. Pressure compensation valve (Boom lower)
14. Pressure compensation valve (Right swing)
15. Pressure compensation valve (R.H. travel forward)
16. Pressure compensation valve (Arm in)
17. Main relief valve
18. Unload valve
19. Unload valve
21. Spool (Service 2)
22. Spool (Service 1)
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
Outside Installed load Free length Installed load
31 Spool return spring length
diameter
417 N 333 N
54.2 × 34.8 51.2 —
{42.5 kg} {34.0 kg}
If damaged or
393 N 315 N
32 Spool return spring 54.5 × 34.8 51.2 — deformed, replace
{40.1 kg} {32.1 kg}
spring.
421 N 336 N
33 Spool return spring 54.6 × 34.8 51.2 —
{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, 450-8R 5
(2/5)
6 PC400, 450-8R
1. Safety-suction 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. Safety-suction valve (Service 1)
7. Safety-suction valve (Service 2)
8. 2-stage safety-suction valve (Service 1)
9. Safety-suction valve (Arm Hi in)
10. Safety-suction valve (Bucket curl)
11. Suction valve (Left travel forward)
12. 2-stage safety-suction valve (Boom lower)
13. Suction valve (Right travel forward)
14. Safety-suction 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)
22. LS shuttle valve (Service 2)
23. LS check valve
24. Pressure relief plug
Unit: mm

Free length ×
Installed
25 Suction valve spring length If damaged or
diameter
deformed, replace
5.5 N 4.4 N
46.8 × 7.5 40.6 — spring.
{0.56 kg} {0.45 kg}
1.5 N 1.2 N
26 Check valve spring 11.5 × 4.6 8.5 —
{0.15 kg} {0.12 kg}
PC400, 450-8R 7
(3/5)
8 PC400, 450-8R
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. Safety-suction valve (In)
9. Regeneration circuit check valve
10. Safety-suction 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 ×
Installed
22 Spool return spring length If damaged or
diameter
deformed, replace
19.6 N 15.7 N
50.0 × 14.4 42.0 — spring.
{2.0 kg} {1.6 kg}
5.9 N 4.71 N
{0.6 kg} {0.48 kg}
PC400, 450-8R 9
(4/5)
10 PC400, 450-8R
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 safety-suction valve (Lower)
12. Regeneration circuit check valve
13. Suction valve (Raise)
14. Pressure compensation valve (Raise)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (Forward)
19. Spool
20. Suction valve (Forward)
21. Suction valve (Reverse)
22. Pressure compensation valve (Reverse)
Bucket valve
24. Pressure compensation valve (Curl)
25. Spool
26. Safety-suction valve (Curl)
27. Safety-suction valve (Dump)
28. Pressure compensation valve (Dump)
Unit: mm
Free length ×
Installed
29 Spool return spring length
diameter
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}
If damaged or
178 N 142 N
31 Spool return spring 64.5 × 32.3 63.0 — deformed, replace
{18.1 kg} {14.5 kg}
spring.
35.3 N 28.2 N
{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, 450-8R 11
(5/5)
12 PC400, 450-8R
Boom Hi and arm Hi valve
1. Boom Hi check valve

2. Quick return valve
3. Pressure compensation valve (Arm Hi in)
4. Arm Hi spool
5. Safety-suction valve (Arm Hi in)
6. Boom Hi spool
7. Suction valve (Boom Hi raise)
8. Pressure compensation valve (Boom Hi raise)
Service valve 1
9. LS shuttle valve
10. Pressure compensation valve
11. Spool
12. 2-stage safety-suction valve
13. Safety-suction valve
Service valve 2
16. Spool
18. Unload valve
20. LS bypass plug
PC400, 450-8R 13
CLSS
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with variable capacity piston
tem, which has the following characteristics: pumps, control valves, and respective actuators.
q The hydraulic pump is configured with pump
q Fine control not influenced by load body, PC valve and LS valve.
q Controllability enabling digging even with fine
control
q Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
q Energy saving using variable pump control
14 PC400, 450-8R
Basic principle
1. Pump swash plate angle control
q The pump swash plate angle (pump delivery) is q The pump swash plate angle shifts toward the
controlled so that LS differential pressure (dPLS) maximum position if LS differential pressure
(the difference between pump pressure PP and (dPLS) is lower than the set pressure of the LS
control valve outlet port LS pressure PLS) (load valve (when the actuator load pressure is high).
pressure of actuator) is constant. If it becomes higher than the set pressure (when
q [LS differential pressure (dPLS) = Pump dis- the actuator load pressure is low), the pump
charge pressure (PP) – LS pressure (PLS)] swash plate angle shifts toward the minimum po-
sition.
q If it becomes higher than the set pressure (when
the actuator load pressure is low), the pump
swash plate angle shifts toward the minimum po-
sition.
LS differential pressure (dPLS) and pump swash

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

pump”.
PC400, 450-8R 15
2. Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to balance
the load.
q When actuators are operated together, the pres-
sure difference (EP) between the upstream (inlet
port) and downstream (outlet port) of the spool of
each valve becomes the same regardless the
size of the load (pressure).
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.
16 PC400, 450-8R
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, 450-8R 17
Functions and operation by valve
Hydraulic circuit diagram and the name of valves
18 PC400, 450-8R
1. Arm valve 2 stage: 17.2 ± 0.5 MPa{175 ± 5

2. R.H. travel valve kg/cm2}
3. Swing valve 42. 2-stage safety-suction valve
4. Boom valve Set pressure: 1 stage: 28.4 ± 0.5 MPa{290 ± 5
5. L.H. travel valve
kg/cm2}
6. Bucket valve
2 stage: 14.7 ± 0.5 MPa{150 ± 5
7. Boom Hi valve
8. Arm Hi valve kg/cm2}
9. Service valve 1 43. Safety valve
10. Service valve 2 Set pressure: 38.2 ± 0.5 MPa{390 ± 5 kg/cm2}
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
34. Boom Hi check valve
35. Main relief valve (bucket side)
Set pressure:
36.1 ± 0.25 MPa{367.5 ± 2.5 kg/cm2}(112 l/min)
When digging force increased:
38.2 ± 0.25 MPa{389.5 ± 2.5 kg/cm2}(110 l/min)
36. Main relief valve (arm side)
Set pressure:
36.1 ± 0.25 MPa{367.5 ± 2.5 kg/cm2}(112 l/min)
When digging force increased:
38.2 ± 0.25 MPa{389.5 ± 2.5 kg/cm2}(110 l/min)
37. Unload valve (bucket side)
Cracking pressure: 3.1 ± 0.5 MPa{32 ± 5 kg/cm2}
38. Unload valve (arm side)
Cracking pressure: 3.1 ± 0.5 MPa{32 ± 5 kg/cm2}
Set pressure: 17.2 ± 0.5 MPa{175 ± 5 kg/cm2}
Set pressure: 38.2 ± 0.5 MPa{390 ± 5 kg/cm2}
41. 2-stage safety-suction valve
Set pressure: 1 stage: 20.1 ± 0.5 MPa{205 ± 5
kg/cm2}
PC400, 450-8R 19
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 min- q Pressure of pump circuit (3) is received by the
imum pump swash plate angle while all control end of valve (2).
valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set load pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
of spring (5) inside the valve (this pressure will q Pressurized oil of pump circuit (3) stops at valve
be P1). (2), and the pressure rises as no relief is avail-
q Since LS pressure is drained from the LS bypass able.
valve, LS pressure C tank pressure C 0 MPa {0 q When this pressure becomes larger than the
kg/cm22}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure – LS circuit
pressure during unloading is larger than the
pump LS control pressure, the signal is output to
minimize the pump swash plate angle.
20 PC400, 450-8R
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 (dPLS) of dis- q The pump discharge pressure (PP) and LS pres-
charge for the portion of minimum swash plate sure (PLS) become approximately the same as
angle will be equal to P1 pressure. each has not flow at the upstream and down-
stream of the spool, and LS differential pressure
(dPLS) becomes 0 kg/cm2.
q As LS differential pressure (dPLS) is lower than
the LS set pressure of LS valve, LS valve is ac-
tuated 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 an-
gle by the cut-off function of PC valve.
PC400, 450-8R 21
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 me-
ter-in downstream pressure) of pressure com-
pensation 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 pres-
sure.
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 pres-
sure 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.
22 PC400, 450-8R
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 pre-
vent a sudden change of hydraulic pressure.
q Bypass flow from LS bypass valve (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool (2)
and LS shuttle valve (4).
q Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.
PC400, 450-8R 23
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) are

q Pressure compensation valve works as the load not interconnected in an integrated pressure
check valve. compensation valve.
q If the pump pressure (LS pressure) is lower than q If high peak pressure is generated at port (C),
the load at port (c), shuttle valve (3) in pressure valve (7) does not collide with the valve cham-
compensation valve piston (4) interconnects ber.
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 before
valve (2) to the closing direction. 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 circuit
or repetitive peak pressure occurs continuously
(example: when using the breaker).
q To prevent this, a pressure compensation valve
with integrated valve (2) and piston (4) is used.
q With the present machine, this device is adopted
for the bucket valve (cylinder bottom) and the
service valve.
24 PC400, 450-8R
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) pres-
sure] becomes equivalent to all the spools in op-
eration.
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 di-
rection (to the right) under the LS circuit pressure
from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
PC400, 450-8R 25
3.Pressure compensation valve area ratio
Function
q The state of division changes according to the
area ratio of pressure compensation portion (A1)
and (A2). Area ratio = (A2)/(A1)
q If area ratio = 1 : the spool meter-in downstream
pressure will be equal to the maximum load
pressure, and the pressure will be divided ac-
cording 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.
26 PC400, 450-8R
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 separated.
PC400, 450-8R 27
2.In the case of travel
Outline
q Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (3) is adopted.
28 PC400, 450-8R
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 cylin- q If the cylinder head pressure is lower than the
der bottom to the cylinder head when the boom bottom pressure, pressurized oil (A) from the cyl-
is lowered and increases flow to the cylinder inder bottom flows to drain circuit (B) from the
head. 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, 450-8R 29
2.If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
30 PC400, 450-8R
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 provid- q If the cylinder head pressure is higher than the
ed from the cylinder head to the bottom increas- bottom pressure, pressurized oil (A) from the cyl-
es the cylinder speed as the cylinder flow inder head flows to drain circuit (B) from the
involves the pump delivery plus regenerated notch of arm spool (2).
flow. q On the other hand, remaining oil flows to regen-
eration 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, 450-8R 31
2.If the cylinder head pressure is lower than the bottom pressure
Function
q Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
32 PC400, 450-8R
Merge-divider valve
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) discharged q Since pilot pressure (PS) is OFF, output pres-
from the two pumps or divides (to respective sure from PPC valve is 0 MPa {0 kg/cm2}.
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) discharged
from the two pumps at ports (E) and (F) and
sends to necessary control valve.
q Since pilot pressure (PS) is OFF for LS spool (3),
it is pressed to the right by spring (4), and ports
(A) – (D) and ports (B) – (C) are interconnected.
q Forwards LS pressure led from respective con-
trol valve spools to LS circuits (5), (6), (7) and (8)
to all the pressure compensation valves.
PC400, 450-8R 33
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 output
pressure from the PPC valve, interconnects
ports (A) and (C) and divides other ports.
q Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
34 PC400, 450-8R
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 while q Since pilot pressure (BP) is OFF, piston (3) is
the swinging and work equipment are in compressed to the left by spring (2).
bined operation. q When swing-operated, swing LS pressure (P1)
q Prevents high pressure generated during swing enters port (A) after passing swing spool (5).
drive and improves operability of work equip- q Valve (1) is pressed to the left and ports (A) and
ment. (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 interconnec-
tion between ports (A) and (B) is closed.
q Swing LS pressure (P1) stops flowing to LS shut-
tle valve (8).
q If swing LS pressure (P1) rises, other LS circuits
are not affected.
a The illustration shows the state of simultaneous

operation of swinging and R.H. travel. [(BP)
pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
PC400, 450-8R 35
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).
36 PC400, 450-8R
2. During neutral and when load pressure (P2) is 3. When load pressure (P2) is high
low q Load pressure (A2) increases with the operation
a When load pressure (A2) is lower than self pres- of digging, etc, and the pump discharge increas-
sure reducing valve output pressure (PR) es accordingly.
q Pressure (P2) increases to [(fd area × P2 pres-
q Valve (7) is pressed to the closing direction of sure) = force of spring (8) + (fd area × PR pres-
circuit between ports (P2) and (A2) by spring (8) sure)], and valve (7) moves to the right to the
and under pressure (PR) (which is 0 MPa {0 stroke end.
kg/cm2}). q As a result, opening between ports (P2) and (A2)
q When pressurized oil flows in from port (P2), a increases, and the pass resistance reduces, re-
balance is reached due to [(fd area × P2 pres- ducing the engine horsepower loss.
sure) = force of spring (8) + (fd area × PR pres- q When pressure (PR) rises above the set pres-
sure)]. sure, poppet (11) opens.

q Adjusts valve (7) opening to keep pressure (P2) q Pressurized oil flows from port (PR) to orifice (a)
at a constant level over pressure (PR). in spool (14), then flows to seal drain port (TS)
q When pressure (PR) rises above the set pres- from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and af-
q Pressurized oil flows from port (PR) to orifice (a) ter orifice (a) in spool (14) and then spool (14)
in spool (14), then flows to seal drain port (TS) moves to close the pass between ports (P2) and
from poppet (11) opening. (PR).
q Differential pressure is generated before and af- q Pressure (P2) is reduced by the opening at this
ter orifice (a) in spool (14) and then spool (14) time and adjusted to a constant pressure (the set
moves to close the pass between ports (P2) and pressure) and supplied as pressure (PR).
(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, 450-8R 37
4.When abnormally high pressure is generated

q If pressure (PR) of self pressure reducing valve
becomes abnormally high, ball (16) contracts
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.
38 PC400, 450-8R
Travel junction valve

1.When pilot pressure is turned ON
Function Operation
q This valve connects the L.H. and R.H. travel cir- q Pilot pressure (PST) from the travel junction so-
cuits through travel junction valve so that the hy- lenoid valve compresses spring (1), and travel
draulic oil will be supplied evenly to both travel junction spool (2) moves to the left to the stroke
motors to improve machine's straight travel per- end.
formance. q Junction circuit between port (PTL) (L.H. travel
q When the machine is steered, outside pilot pres- circuit) and port (PTR) (R.H. travel circuit) is
sure (PST) closes the travel junction valve to im- closed.
prove steering performance.
PC400, 450-8R 39
2.When pilot pressure is turned OFF
Operation
q If pilot pressure (PST) from the solenoid valve is q If the oil flow rates to the L.H. and R.H. travel mo-
0 MPa {0 kg/cm2}, travel junction spool (2) is tors become different from each other, the oil
pressed to the right side by the force of spring (1) flows through the route between port (PTL), trav-
and the passage between ports (PTL) and (PTR) el junction spool (2), and port (PTR) so that the
is opened. oil flow rates to both motors will be equalized
again.
40 PC400, 450-8R
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) is
the stroke of each spool of the boom, arm, and drained through orifices (5) and (6) of pistons (3)
bucket using the pilot pressure of travel PPC and (4) in the travel spring case and the travel
valve while climbing a steep grade, raising the PPC valve.
boom, digging with arm, dumping, bucket-dig- q When operated for boom raising (or arm digging,
ging or operating dump. dumping, bucket digging, dumping), spool (1)
q When controlling the stroke of the boom, arm moves to the left until it makes contact with the
and/or bucket, pilot pressure of travel PPC valve end face of spring casing (2) (st0).
passes through the circuit inside the control
valves to actuate the system.
PC400, 450-8R 41
2.When traveling
Operation
q If the right travel lever is set in the reverse (or for- q When operated for boom raising (or arm in, out,
ward) direction, pilot pressure from the PPC bucket curl, dump), spool (1) moves to the left.
valve presses spool (7) to the left (or right). q Maximum stroke of the spool is limited to (st1) for
q Spool (7) pushes piston (3) to close orifice (5) the amount of movement (st2) of piston (8) to the
and shut off stroke regulation signal chamber (a) right.
and the drain circuit of the travel PPC valve.
q At this time, the right travel reverse (or forward)
lever is set, pilot pressure from the PPC valve is
applied through orifice (6) of piston (4) to the left
end of piston (8) to push piston (8) to the right.
42 PC400, 450-8R
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)[= f(d1) area – f(d2) area] caused by the dif-
ference 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, 450-8R 43
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 ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q The holding pressure of boom cylinder bottom
works on the ring-shaped area (S) caused by the
difference between outside diameter (d1) of pop-
pet (5) and seat diameter (d2) to move it to the
right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom
are shut off.
44 PC400, 450-8R
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 poppet
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, 450-8R 45
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) [= f(d1) area – f(d2) area] caused by
the difference between the outside diameter (d1)
of poppet (5) and the seat diameter (d2) to move
it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.
46 PC400, 450-8R
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 ori-
fice (a) of poppet (5) is closed by pilot piston (2).
q The holding pressure of arm cylinder head works
on ring-shaped area (S) caused by the differ-
ence between outside diameter (d1) of poppet
(5) and seat diameter (d2) to move it to the right.
q The sum of this force and the force of spring (4)
closes poppet (5).
q Pressurized oil from the control valve and the
holding pressure of the arm cylinder head are
shut off.
PC400, 450-8R 47
3.When arm IN
Operation
q If arm is set to IN, pilot piston (2) is pushed by the
pilot pressure from the PPC valve.
q Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T), and
the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
48 PC400, 450-8R
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 in-
boom cylinder bottom circuit, the pressurized oil stalled to the arm cylinder head circuit, the boom
in port (B) pushes check valve (6) open, then cylinder bottom circuit pressure force or arm cyl-
safety valve (3) operates. inder head circuit pressure force, whichever hav-
ing higher pressurized oil, pushes check valve
(6) or (6A) open to actuate safety valve (3).
PC400, 450-8R 49
Quick return valve

1.When arm OUT
Function
q When arm is set to out, large volume of oil re-
turns from the cylinder bottom.
q Reduces this pressure loss.
Operation
q When arm is set to out, pilot piston (1) is pushed q Or (fd2 pressure receiving force > fd1 pressure
by the pilot spool from the PPC valve. receiving force + spring force)
q Pressurized oil in chamber (b) inside the valve is q Valve (2) is pressed to the left and pressurized
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 directly
orifice (a) o chamber (b) o orifice (c) o drain 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 [fd2 area (S2) (seat
diameter area)] on the side of port (A) increases
by the sum of the pressure receiving force of
pressure receiving portion[fd1 area (S1)] on the
chamber (b) side of valve (2) and the spring
force.
50 PC400, 450-8R
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, 450-8R 51
Lift check valve

Function 2.While engine is running
q This valve applies back pressure to the drain cir- q Output pressure (PR) of the self pressure reduc-
cuit to prevent generation of negative pressure ing valve is conducted to through the control
on each actuator (motors, cylinders, etc.). valve to spring chamber (c) of lift check valve (3).
q Output pressure (PR) applied to spring chamber
Operation (c) is applied to the left end of valve (1) (area of
1.While engine is stopped fd) to push valve (1) to the right.
q Pressurized oil is not fed to the self pressure re- q At this time, pressure (PA) of drain circuit (a) of
ducing valve from the pump, and valve (1) is the control valve is applied to the right end of
pressed to the right by the force of spring (2). valve (1) (area of fd1) to push valve (1) to the
q Drain circuit (a) of the control valve is connected left.
with port (T) through orifice (b) of valve (1). q Valve (1) strikes balance to make the back pres-
sure equal to (PA) in the equation below.
PA = (Area of fd) × PR + force of spring (2)
Area of fd1
52 PC400, 450-8R
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 high-
er.
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 completes
the setting of the 2nd stage.
1.If pilot pressure (P) is OFF: Low-pressure set-

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

ting
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, 450-8R 53
2-stage safety-suction 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 pressure q The safety set pressure is determined by spring
in two stages, and make the low-pressure set- (1) installed load.
ting smaller.
q Enables to relieve a load without lever operation 1.If pilot pressure is OFF (high-pressure setting)
if high load is applied to the cylinder. q Since pilot pressure (P) is OFF, piston (2) is
q Improves work efficiency and reduces machine pressed to the left by spring (3). [Spring (1) in-
body vibration. stalled 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 circuit
via passage (C) and chamber (D).
54 PC400, 450-8R
2.If pilot pressure is ON (low-pressure setting)

q If the pilot pressure (P) is ON, the pilot pressure
is led to section (A) via passage (B) and works
on the pressure-receiving bore section (d2 – d1).
q This pilot pressure contracts spring (3), and pis-
ton (2) moves to the right until making contact
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, 450-8R 55
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 ratio
1. Valve 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 orifice
6. Screw (d).
7. Locknut q Pressurized oil of cylinder port is led to chamber
8. Cap (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).
56 PC400, 450-8R
Operation when jointly operated with a high-load work equipment (such as the boom raising)
q Both of the pump discharge pressure (P) and LS q If the difference between the pump discharge
pressures are determined by other equipment's pressure (P) and cylinder port pressure (B) is
pressure, while cylinder port pressure causes larger than the force of spring (5), poppet (4) is
the attachment to operate. pressed to the right.
q If the difference between the pump discharge q Pump discharge pressure (P) flows to orifice (a)
pressure (P) and cylinder pressure is smaller and chamber (g) and is interconnected to cylin-
than the force of spring (5), the balance of forces der port via passages (b) and (c).
applying to valve (1) may be expressed with the q Differential pressure is generated between 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 re-
duced.
A1: Area of fd1 q A state is reached where the area ratio has be-
A2: Area of fd2 come smaller.
F: Force of spring q Valve (1) moves to the right, and the flow in-
P: Pump discharge oil pressure creases from the pump to the cylinder.
PC400, 450-8R 57
Attachment circuit selector valve
ACC: To accumulator TS: To hydraulic oil tank

ATT: To attachment V: To control valve
P1: From attachment selector solenoid valve 1. Spool
T: To hydraulic oil tank 2. Spring
Unit: mm

Free length ×
Installed If damaged or
3 Spool return spring length deformed, replace
diameter
spring.
834 N 667 N
132 × 29 114.5 —
{85.0 kg} {68.0 kg}
58 PC400, 450-8R
Function
q When a breaker is installed, the return oil from q When other attachments (crusher, etc.) are in-
the breaker does not pass through the main stalled, the attachment and the main valve are
valve, but returns directly to the hydraulic tank. interconnected.
Operation 2.When breaker is installed

1.When attachment other than breaker is in- q Pilot pressure (P1) from the attachment circuit
stalled selector solenoid valve compresses spring (2),
q Spool (1) is pressed to the left by the force of moving spool (1) rightward to the stroke end.
spring (2). q Ports (ATT) and (V) are shut off and ports (ATT)
q Ports (ATT) and (V) are interconnected and and (T) are interconnected.
ports (ATT) and (T) are shut off. Attachment is q Pressurized oil returning from the breaker re-
thus interconnected to the control valve. turns directly to the hydraulic tank via port (T)
without passing through the control valve.
PC400, 450-8R 59
Holding valve
(For the boom and arm)
60 PC400, 450-8R
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 ×
Installed
7 Check valve spring length
diameter
12.7 N 10.2 N If damaged or
20.8 × 12.2 13.5 —
{1.3 kg} {1.04 kg}
deformed,
58.8 N 47.1 N
8 Spool return spring 41.1 × 9.6 35.0 — replace spring.
{6.0 kg} {4.8 kg}
78.5 N 62.8 N
{8.0 kg} {6.4 kg}
126 N 100 N
{12.8 kg} {10.2 kg}
PC400, 450-8R 61
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 pres- q If piping (A) is broken between the control valve
sure of the cylinder led from port (CY) to cham- and the work equipment cylinder, chambers (a)
ber (b). and (b) are shut off in the same way as the piping
q At the neutral, pilot pressure led to port (PI) from is free from damages.
the PPC valve is 0 MPa {0 kg/cm2}. q Pressure for the work equipment cylinder is held
q Spool (1) is pressed to the left by the force of to prevent a sudden drop of the work equipment.
springs (2) and (3)
q Chambers (a) and (b) are shut off.
q No pressurized oil flows between the control
valve and the work equipment cylinder.
q Accordingly, the work equipment is held in posi-
tion.
q If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by the
holding pressure of the work equipment cylinder.
q Chambers (b) of L.H. and R.H. holding valve for
the boom are interconnected by port (PCY).
q Chambers (b) will have the same pressure if the
L.H. and R.H. holding valves have a difference in
leakage.
62 PC400, 450-8R
2. When pressurized oil flows from the main

valve to the cylinder
When the piping is not broken

q Pressurized oil led to chamber (a) from the con-
trol valve becomes higher than the combined
force of pressure from work equipment cylinder
circuit chamber (b) and spring (6).
q Check valve (5) opens and chambers (a) and (b)
are interconnected.
q Pressurized oil flows from the control valve to the
work equipment cylinder.
If the piping is broken

q If piping (A) between the control valve and the
work equipment cylinder is broken, pressurized
oil in chamber (a) flows outside from the dam-
aged 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, 450-8R 63
3. When returning pressurized oil to the main

valve from the work equipment cylinder
When the piping is not broken If the piping is broken

q Holding pressure of the work equipment cylinder q If piping (A) broken between the control valve
is led to chamber (b) and check valve (5) closes. and the work equipment cylinder.
q Pilot pressure from the PPC valve is led to port q Pressurized oil in chamber (a) flows out to the
(PI) and reaches [Pilot Pressure > Force of broken portion but resupplied from chamber (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 posi- spool (1), a sudden drop of the cylinder is pre-
tion. (1st stage stroke) vented.
q At this point, chambers (a) and (b) are not inter-
connected.
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.
64 PC400, 450-8R
PC400, 450-8R 65
PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R Hydraulic excavator
©2011 KOMATSU
All Rights Reserved
66
SEN04251-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 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, 450-8R 1
Valve control 1
1. Travel PPC valve Lever positions

2. Service PPC valve A. Hold
3. Service pedal B. Boom (RAISE)
4. L.H. travel lever C. Boom (LOWER)
5. R.H travel lever D. Bucket (DUMP)
6. R.H. PPC valve E. Bucket (CURL)
7. R.H. work equipment control lever F. Hold
8. Solenoid valve G. Arm (IN)
9. Accumulator H. Arm (OUT)
10. Control valve J. Swing (RIGHT)
11. Hydraulic pump K. Swing (LEFT)
12. Junction box L. Neutral
13. L.H. work equipment control lever M. Travel (REVERSE)
14. L.H. PPC valve N. Travel (FORWARD)
2 PC400, 450-8R
PC400, 450-8R 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, 450-8R
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
Free length × Installed Installed Installed
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
PC400, 450-8R 9
10 PC400, 450-8R
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.
12 Metering spring 26.5 × 8.15 24.9
{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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 17
Service PPC valve (with EPC valve) 1
a For the details of operation, see the paragraph of “Work equipment swing PPC valve.”
18 PC400, 450-8R
P: From self pressure reducing valve

P1: To service valve
P2: To service valve
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
Free length x Installation Installation Installation
Free length
9 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed, replace
33.9 x 15.3 28.4 — spring.
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 x 8.10 22.0
{1.70 kg}
—
{1.36 kg}
PC400, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 23
Center swivel joint 1
1. Cover A1: To L.H. travel motor REVERSE port PB

2. Body A2: From control valve port A2
3. Slipper seal B1: To L.H. travel motor FORWARD port PA
4. O-ring B2: From control valve port B2
5. Shaft C1: To R.H. travel motor REVERSE port PA
C2: From control valve port A5
D1: To R.H. travel motor FORWARD 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, 450-8R
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, 450-8R 25
26 PC400, 450-8R
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
21 Spool return spring Outside diameter length load load
427 N 341 N If damaged or
62.5 × 32.0 42.0 —
3.04 N 2.45 N spring.
22 Check valve spring 62.5 × 20.0 39.0
{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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 37
38 PC400, 450-8R
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
6.96 N 5.59 N deformed, replace
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, 450-8R 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, 450-8R
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, 450-8R 41
Reverse prevention valve
42 PC400, 450-8R
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, 450-8R 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, 450-8R
PC400, 450-8R 45
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
46 PC400, 450-8R
Unit: mm
Cylinder
size Shaft Hole clearance limit
–0.036 +0.261 0.083 –
Boom 100 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 —
Clearance between –0.090 +0.070 0.280
cylinder –0.036 +0.195 0.135 –
3 bottom support pin and
Arm 110
–0.090 +0.099 0.285
—
bushing –0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277
PC400, 450-8R 47
SEN04251-01

© 2011 KOMATSU
All Rights Reserved
48
SEN04252-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 4
PC400, 450-8R 1
Work equipment 1
2 PC400, 450-8R
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
Clearance between connecting pin –0.036 +0.172 Replace

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

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, 450-8R 3
Dimensions of components 1
1. Dimension of arm
4 PC400, 450-8R
Unit: mm
PC400-8R PC450-8R
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, 450-8R 5
2. Dimension of bucket
6 PC400, 450-8R
Unit: mm
PC400-8R, PC400LC-8R PC450-8R, PC450LC-8R
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, 450-8R 7
SEN04252-00

© 2008 KOMATSU
All Rights Reserved
8
SEN04253-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Cab and its attachments
Air conditioner piping ...................................................................................................................................... 2
PC400, 450-8R 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, 450-8R
PC400, 450-8R 3
SEN04253-00

© 2008 KOMATSU
All Rights Reserved
4
SEN04254-02
PC400, 450-8R
SEN04254-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up

maintenance standard
Electrical system
Engine control ............................................................................................................................................. 2

Electronic control system ............................................................................................................................ 12
Monitor system............................................................................................................................................ 37
Sensors....................................................................................................................................................... 64
KOMTRAX system...................................................................................................................................... 67
PC400, 450-8R 1
Engine control
1. Battery relay Outline

2. Battery q The engine can be started and stopped with only
3. Starting switch starting switch (3).

4. Fuel control dial
5. Starting motor
6. Engine throttle controller
7. Pump controller
2 PC400, 450-8R
Operation of system Stopping engine

Starting engine q When detecting that the starting switch is set to
q When the starting switch is turned to the the “STOP” position, the engine controller cuts
“START” position, the starting signal flows to the fuel injection to stop the engine.
the starting motor. Then, the starting motor 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 decel-
eration, 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.
PC400, 450-8R 3
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 en-
gine controller.
q The hatched area in the graph shown at right is
the abnormality detection area.
4 PC400, 450-8R
Engine controller
q Meanings of signal classes in the terminal table CN-CE01

shown below are as follows. Input/out-
Pin No. Signal name
put
A: Power Supply
11 EGR valve C
B: Input 12 NC(*) —
C: Ground/Shield/Return 13 Engine oil pressure sensor D
D: Output 14 NC(*) —
15 Coolant temperature sensor D
E: Communication 16 5V electric power supply for sensor A
CN-CE01 17 NC(*) —
Input/out- 18 NC(*) —
Pin No. Signal name
put 19 EGR valve position sensor D
1 NC(*) — 20 NC(*) —
2 NC(*) — 21 NC(*) —
3 Atmosphere sensor D 22 EGR valve (+) B
4 Supply pump #1 (+) B 23 Boost temperature sensor D
5 Supply pump #1 (–) C 24 NC(*) —
6 CAN(+) C 25 Common rail pressure sensor D
7 NC(*) — 26 Buckup sensor D
8 CAN(+) B 27 NE sensor (+) D
9 Supply pump #2 (+) B
10 Supply pump #2 (–) C *: Never connect to NC or malfunctions or failures
will occur.
*: Never connect to NC or malfunctions or failures
will occur.
PC400, 450-8R 5
CN-CE01 CN-CE02
Input/out- Input/out-
Pin No. Signal name Pin No. Signal name
put put
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(*) —
46 CAN(+) E
*: Never connect to NC or malfunctions or failures 47 CAN(–) E
will occur. 48 NC(*) D
PWM OUTPUT
49 D
(Power train relay output)
CN-CE02
50 NC(*) D
Input/out-
Pin No. Signal name
put *: Never connect to NC or malfunctions or failures
1 NC(*) B
will occur.
2 NC(*) B
3 NC(*) B
4 NC(*) B CN-CE03
5 NC(*) B Input/out-
Pin No. Signal name
6 NC(*) B put
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 occur.
will occur.
6 PC400, 450-8R
Rotation sensor
1. Connector
2. Sensor
3. O-ring
Oil pressure switch
1. Connector
2. Sensor
3. O-ring
PC400, 450-8R 7
Ambient pressure sensor
1. Connector
2. Pressure import port
Boost pressure sensor
1. O-ring
2. Sensor
3. Connector
8 PC400, 450-8R
Boost temperature sensor
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor, hydraulic oil temperature sensor
1. Connector
2. Sensor
3. O-ring
PC400, 450-8R 9
EGR valve stroke sensor
1. Core
2. O-ring
3. Sensor
4. Connector
10 PC400, 450-8R
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
PC400, 450-8R 11
Electronic control system
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 func-

Electronic control system
tion
Swing control function
Travel control function
Attachment flow control and circuit selector

function
(if equipped)
Self-diagnosis function
a For the self-diagnosis function, see “Troubleshooting“.
12 PC400, 450-8R
Machine control system diagram
PC400, 450-8R 13
14 PC400, 450-8R
1. Engine and pump composite control function
PC400, 450-8R 15
Function 1) Control method in each mode

q This function allows the operator to select proper P and E modes
engine torque and pump absorption torque ac- q Matching point in P mode: Rated speed
cording to the type of work. Four modes are pro-
vided: P, E, B and L. Using the work mode switch Mode Matching point
on the monitor panel, the operator is required to 246.3 kΩ/1,850 rpm
P
select one of them. {330 HP/1,850 rpm}
q The pump controller detects the speed of the en- 213.3 kW/1,720 rpm
E
gine governor set with the fuel control dial and {286 HP/1,720 rpm}
the actual engine speed (N) and controls them
so that the pump will absorb all the torque at q If the pump load increases and the pres-
each output point of the engine, according to the sure rises, engine speed (N) lowers. At
pump absorption torque set in 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
controller constantly uses the engine near
the maximum output point.
16 PC400, 450-8R
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 func-
tion to decrease engine speed (N) while
maintaining engine torque (T) constant
along the constant horsepower curve.
This ensures reduced fuel consumption.
PC400, 450-8R 17
2) Function to control pump during travel 3) Function to control when emergency

q Traveling the machine in E or B mode pump drive switch is turned on
leaves the working mode unchanged, but q Even if any abnormality occurs in the con-
raises the pump absorption torque and troller or sensor, setting emergency pump
engine speed (N) to values same as drive switch (1) to the “ON” position ac-
those in P mode. tivates the machine with an absorption
q If the machine travels in L mode, the torque approximately equivalent to that in
working mode and engine speed (N) do E mode.
not change, but the pump absorption In this case, a constant current flows from
torque is increased. the battery to the EPC valve for PC and
therefore, the oil pressure is sensed by
only the EPC valve for PC.
18 PC400, 450-8R
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 in-
crease the digging force, etc.
PC400, 450-8R 19
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/cm2}. If the 2-stage re-
pressure output from the LS-EPC valve to lief function is turned on, however, the re-
LS valve to change the change point (LS lief pressure rises to about 37.2 MPa {380
set differential pressure (DLS)) of the
kg/cm2}. By this operation, the hydraulic
pump discharge in the LS valve.
force is increased further.
q By this operation, the start-up time of the
pump discharge is optimized and the
composite operation and fine control per- Operating condition for turning on Relief pressure
2-stage relief function
formance is improved.
q During travel
q When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
q When boom is lowered O
q When power maximizing function is 37.2 MPa
turned on {380 kg/cm2}
q 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.
20 PC400, 450-8R
3. Power maximizing and machine push-up function
Function
q The power maximizing function allows the oper-
ator to increase power for a certain time by oper-
ating the left knob switch.
q The machine push-up function allows the opera-
tor to increase the boom pushing force by oper-
ating the machine push-up switch.
PC400, 450-8R 21
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
shown below. Switch
function
Setting of safety valve at
Function Setting boom cylinder head
OFF 14.7 MPa
Matching at rated ouptut
Engine and pump control
point {150 kg/cm2}
34.8 MPa Setting of safety valve at
{355 kg/cm2} boom cylinder head
ON 28.4 MPa
2-stage relief function O
37.2 MPa {290 kg/cm2}
{380 kg/cm2}
Software cut-off function Cancel
q These settings are automatically reset af-

ter 8.5 seconds when the switch is
pressed.
22 PC400, 450-8R
4. Auto-deceleration function
Function
q The auto-deceleration function automatically re-
duces the engine speed to its medium speed
range when the all control levers are set in NEU-
TRAL while waiting for a dump truck or work to
reduce the fuel consumption and noise.
q If any lever is operated, the engine speed in-
stantly returns to the speed set with the fuel con-
trol dial.
Operation
When control levers are set in neutral
q If all the control levers are kept to NEUTRAL for
4 sec. during operation at a engine speed above
a decelerator operation level (approximately
1,300 rpm), this function lowers the engine
speed to the deceleration operation level (ap-
proximately 1,300 rpm) and keeps it until you op-
erate any lever.
When any control lever is operated
q If you operate any control lever while the engine
speed is kept at the deceleration operation level,
the engine speed instantly rises to the level set
with the fuel control dial.
PC400, 450-8R 23
5. Auto-warm-up and overheat prevention function
Function
q The engine automatic warm-up function increas-
es 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 temper-
ature is too high during operation to protect the
engine from overheating.
24 PC400, 450-8R
1) Auto-warm-up function
q After the engine is started, if the engine coolant temperature is low, the engine speed is raised au-
tomatically 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 sec.
Manual
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: Below
Work mode: Travel 95 °C
Hydraulic oil temperature:
Engine speed: Keep as is. q Under above condition, controller
Above 95 °C
Lower travel speed. is set to condition before operation
of function. (Automatic reset)

Hydraulic oil or coolant temperature:
Hydraulic oil or coolant Work mode: P or E mode Below 100 °C
temperature: Engine speed: Keep as is. q Under above condition, controller
Above 100 °C Lower pump discharge. is set to condition before operation

Work mode: P, E, B or Lmode
Hydraulic oil or coolant Below 102 °C
Engine speed: Keep as is.
temperature: q Under above condition, controller
Monitor alarm lamp: Lights up.
Above 102 °C is set to condition before operation
Lower pump discharge.

Below 105 °C
Work mode: Any mode
Hydraulic oil or coolant Fuel control dial: Return to low idle
Engine speed: Low idle
temperature: position once.
Monitor alarm lamp: Lights up
Above 105 °C q Under above condition, controller
Alarm buzzer: Sounds
is set to condition before operation
of function. (Manual reset)
PC400, 450-8R 25
6. Swing control function
Function
The swing lock and swing holding brake function are
provided as a swing control function.
26 PC400, 450-8R
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function
tion when swing lock switch is turned on
q The swing lock function (manual) is used q If swing lock switch (1) is turned on, the
to lock machine from swinging at any po- pump cut-off function is cancelled and the
sition. 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
q Operation of swing lock switch and swing condition, the hydraulic oil temperature
lock/holding brake rises quickly and the warm-up time can be
shortened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in neu-
tral, swing brake operates
Swing
in about 7 sec.
OFF OFF holding
If swing lever is operated,
brake
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 oper-
lock
ated, 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 hold- ON OFF

ing brake (when controller has (when controller is nor-
release switch trouble) maly)
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock
Swing lock holding
Swing brake is turned is turned
is canceled. brake is
on. on.
turned on.
PC400, 450-8R 27
7. Travel control function
Function
q The machine is provided with a function that en-
sures 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.
28 PC400, 450-8R
1) Pump control function during travel 2) Travel speed change function

q If the machine travels in a work mode oth- 1] Manual change with travel speed switch
er than P mode, the work mode and the If one of Lo, Mi and Hi is selected with the
engine speed are kept as they are and the travel speed switch, the pump controller
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.
Lo (Low Mi (Mid- Hi (High

Travel speed switch
speed) dle speed) speed)
Pump capacity (%) 90 80 100
Motor capacity Max. Min. Min.
Travel speed (km/h) 3.0 4.2 5.5
2] Automatic change by engine speed

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

pressure
When traveling with the travel speed
switch set to Hi or Mi, if the load
increases, such as when travelling uphill,
and the travel pressure goes above 32.3
MPa {330 kg/cm2} for more than 0.5 sec,
the travel motor capacity will automati-
cally 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.
PC400, 450-8R 29
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).
30 PC400, 450-8R
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 7 PPC oil pressure
switches.
q This sensor detects the operating condition of
each actuator by the PPC pressure and transmit
it to the pump controller.
PC400, 450-8R 31
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 in- to sensors (P) (MPa {kg/cm2}) and output volt-
put circuit of the control valve. age (E) (V) is shown in the figure below.
q It converts the pump discharge pressure into a E = 0.08 {0.008} x P + 0.5
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 re-
sistance of the gauge to change. This causes a
change in the output voltage, which is transmit-
ted to the amplifier (voltage amplifier).
q The amplifier magnifies output voltage (E) and
transmits it to the pump controller.
32 PC400, 450-8R
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.
PC400, 450-8R 33
4) Pump controller
34 PC400, 450-8R
CN-C01 CN-C01
Input/out Input/out-
Pin No. Signal name Pin No. Signal name
put put
1 PWR_IN_BATT Input 52 Service switch Input
2 GND_PWR Input 53 Boom raise pressure switch Input
3 Washer motor output 54 NC(*) —
4 PWR_IN_BATT Input 55 Travel switch Input
5 GND_PWR Input 56 Wiper limit switch Input
6 NC(*) — 57 Window limit switch Input
7 NC(*) — 58 Machin select 4 Input
8 NC(*) — 59 NC(*) —
9 PWR_OUT_5V_0 output 60 Start switch Input
10 NC(*) Input 61 NC(*) —
11 NC(*) Input 62 NC(*) Input
12 NC(*) Input 63 NC(*) —
13 NC(*) Input Input/Out
64 COMM_CAN_L_0
14 Boom lower switch Input put
15 Arm dump switch Input 65 GND_SIG_A —
16 Swing pressure switch Input 66 NC(*) —
17 Arm curl pilot sensor Input 67 NC(*) —
18 GND_SIG_A Input 68 R pump pressure sensor Input
19 Swing lock switch Input 69 NC(*) —
20 NC(*) — 70 NC(*) —
21 Machin select 2 Input 71 NC(*) Input
22 NC(*) — 72 NC(*) —
23 NC(*) — 73 Bucket curl pilot sensor Input
24 PWR_CTR_KEY — 74 Overload pressure sensor —
25 NC(*) — 75 Wiper limit switch (P) Input
26 NC(*) — 76 NC(*) —
27 NC(*) — 77 Machin select 3 Input
28 NC(*) — 78 Overload caution enable switch —
29 Hydraulic–oil temperature Input 79 Start switch (ACC) Input
30 NC(*) — 80 NC(*) —
31 NC(*) — 81 GND_SIG_D —
32 NC(*) —
33 NC(*) — *: Never connect to NC or malfunctions or failures
34 Bucket dump pressure switch Input will occur.
35 NC(*) —
36 Travel steering switch Input
37 GND_SIG_D —
38 Swing prolix switch Input
39 Machin select 5 Input
40 Machin select 1 Input
41 Knob switch Input
42 NC(*) —
43 PWR_CTR_KEY Input
44 GND_SIG_P Input
Input/out
45 COMM_CAN_H_0
put
46 GND_SIG_A Input
47 GND_SIG_A —
48 NC(*) —
49 F pump pressure sensor Input
50 NC(*) —
51 NC(*) —
PC400, 450-8R 35
CN-C02
Input/out-
Pin No. Signal name
put
82 NC(*) —
83 NC(*) —
84 NC(*) —
85 NC(*) —
86 Att circuit change solenoid output
87 Travle speed solenoid output
88 NC(*) output
89 NC(*) —
90 NC(*) —
91 NC(*) —
92 NC(*) —
93 NC(*) —
94 NC(*) —
95 NC(*) output
96 PCQ–EPC (F) output
97 Att flux limit epc output
98 NC(*) —
99 NC(*) —
100 NC(*) —
101 Swing brake solenoid output
102 NC(*) —
103 NC(*) —
104 NC(*) —
105 NC(*) —
106 NC(*) —
107 NC(*) —
108 Battery relay output
109 2-stage relief solenoid output
110 Travel valve solenold output
111 NC(*) —
112 Merge-divider solenoid (Main) output
113 NC(*) —
114 Wiper motor (–) output
115 GND_ACT Input
116 Solenoid power supply Input
117 GND_ACT Input
118 Solenold power supply Input
119 Wiper motor (+) output
120 GND_ACT Input
121 Solenoid power supply Input

will occur.
36 PC400, 450-8R
Monitor system
q The monitor system notifies the operator of ma-

chine status. It monitors the condition of the ma-
chine with sensors installed on various parts of
the machine, processes and immediately dis-
plays 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 tempera-
ture, hydraulic oil temperature and fuel level
q The machine monitor also has various mode se-
lector switches and functions to operate the ma-
chine control system.
PC400, 450-8R 37
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 output
the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
38 PC400, 450-8R
Input and output signals CN-CM03

Input/out-
Pin No. Signal name
put
CN-CM01
RS232C CD for communication ter-
Input/out- 1 Input
Pin No. Signal name minal
put
RS232C RXD for communication
1 Battery power (+24V constantly) Input 2 Input
terminal
2 Battery power (+24V constantly) Input
3 Battery power GND — RS232C SG for communication ter-
3 —
4 Battery power GND — minal
Input/Out- Signal GND for communication ter-
5 Wake-up 4 —
put minal control
6 Relay output Output Communication terminal selection
5 Input
7 — — signal
8 NC(*) — RS232C RTS for communication
6 Output
9 Fuel level Input terminal
10 NC(*) — RS232C TXD for communication
7 Output
11 Charge amount Input terminal
12 Chassis analog signal GND — RS232C DTR for communication
8 Output
13 Light switch Input terminal
14 Key switch (ACC) Input RS232C DSR for communication
9 Input
15 Key switch (C) Input terminal
16 Preheating Input RS232C CTS for communication
10 Input
17 NC(*) — terminal
18 NC(*) — RS232C RI for communication ter-
11 Input
minal
*: Never connect to NC or malfunctions or failures Power GND for communication ter-
12 —
will occur. minal
Input CH1 for communication termi-
13 Input
CN-CM02 nal status
Input/out- Output for communication terminal
Pin No. Signal name 14 Output
put power control
1 NC(*) — Output CH1 for communication ter-
15 Output
2 Engine oil level sensor Input minal control
3 Coolant level sensor Input Output CH2 for communication ter-
16 Output
4 Air cleaner clogging sensor Input minal control
5 Swing lock Input Input CH2 for communication termi-
17 Input
6 NC(*) — nal status
7 NC(*) — Electric power supply for communi-
18 Output
8 CAN terminating resistance — cation terminal
Input/Out-
9 CAN_H
put
Input/Out- CN-CM04
10 CAN_L Input/out-
put Pin No. Signal name
Input/Out- put
11 NC(*) 1 NC(*) —
put
Input/Out- 2 NC(*) —
12 NC(*) 3 NC(*) —
put
4 NC(*) —
*: Never connect to NC or malfunctions or failures 5 NC(*) —
will occur. 6 NC(*) —
7 NC(*) —
8 NC(*) —
9 NC(*) —
10 NC(*) —
11 NC(*) —
12 NC(*) —

will occur.
PC400, 450-8R 39
CN-CM05
Input/out-
Pin No. Signal name
put
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
Electric power supply GND for cam-
5 —
era
6 Camera signal GND1 —
40 PC400, 450-8R
Monitor control, display portion

Monitor portion
PC400, 450-8R 41
1. Hydraulic oil temperature monitor

2. Hydraulic oil temperature gauge
3. Engine coolant temperature monitor
4. Engine coolant temperature gauge
5. KOMTRAX message monitor
6. Air conditioner monitor
7. Wiper monitor
8. Swing lock monitor
9. Engine pre-heating monitor/power maximizing monitor
10. Time/service meter
11. Auto-deceleration monitor
12. Working mode monitor
13. Travel speed monitor
14. ECO indicator
15. Fuel gauge
16. Fuel level monitor
17. Maintenance interval monitor
18. Engine oil pressure monitor
19. Charge level monitor
20. Radiator coolant level monitor
21. Engine oil level monitor
22. Air cleaner clogging monitor
Precautions on the machine monitor display

q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright spots
conform the product specification; such the
condition is quite normal.
q Battery voltage may suddenly drop at en-
gine-start due to ambient temperature or the
condition of the battery. The machine monitor
display may temporarily disappear if it happens;
it is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen hav-
ing a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).
42 PC400, 450-8R
Monitor items and display

Symbol Display item Display method
Swing holding brake

Swing lock switch Display of symbol
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON Flashes
Preheater operates at low temperature and sym-

Automatic preheating bol keeps lighting up for up to about 30 seconds
and then goes off after engine starts.
Preheating Time after setting Display of symbol
0 – 30 sec ON
Manual preheating
30 – 40 sec Flashes
After 40 sec OFF
Power Max. switch Display of symbol

Keeps lighting up.
Power Max. While pressed Goes off after about 9 sec. if switch
is kept pressed.
While released Kept turned OFF.
Engine coolant
temperature
Hydraulic oil tem-
perature
Fuel level See gauge display on next page.
PTO oil tempera-
ture
Engine oil pres-
sure
PC400, 450-8R 43
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge Range Temperature or volume Indicator Buzzer sound

A1 105 Red Q
Engine coolant tem- A2 102 Red
A3 100 Off
perature
A4 80 Off
(°C)
A5 60 Off
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera-
B3 100 Off
ture
B4 85 Off
(°C)
B5 40 Off
B6 20 White
C1 467 Off
C2 381 Off
C3 295 Off
Fuel level (l)
C4 147.5 Off
C5 114 Off
C6 80.5 Red
44 PC400, 450-8R
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 dis-
played.
Check before starting While engine is While engine is run-

Symbol Display item
item stopped ning
Lights up and buzzer

Engine oil pressure q — sounds when abnor-
mal.
Lights up when abnor-

Battery charge q —
mal.
Lights up and buzzer Lights up and buzzer

Radiator coolant level q sounds when abnor- sounds when abnor-
mal. mal.

Engine oil level q —
mal.

Air cleaner clogging q —
mal.
Notice lamp (yellow)/Warning lamp (red).

Maintenance Lights up for only 30 seconds after starting
switch is turned ON.
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 (below B6 or Black on white back-
equivalent) ground
Normal (B6 – B2) No display
High temperature (above B2) White on red back-
ground
PC400, 450-8R 45
Display cate-
Symbol Display item Display range Display method
gory
Green:
Displays state of message
KOMTRAX There is unread message.
(for only machine equipped
message Blue:
with KOMTRAX).
There is unreturned message.
Air condi-
tioner/Heate ONio OFF Displays operating condition.
r
INT ON OFF
Wiper Displays set condition.
Monitor
Working
P, E, L, B, ATT Displays set mode.
mode
Travel Lo Mi Hi
Displays set speed.
speed
Auto-decel-
ONio OFF Displays operating condition.
eration
Displays average work load

Green:
in 1 minute on 10 levels.
ECO indica- Work load is light – medium.
ECO indicator (Does not display if ECO dis-
tor Orange:
play is set OFF in service
Work load is heavy.
menu.)
Service Displays operating time.

Service meter meter indi- While service meter is working (Changes to clock if F4 is
cator depressed.)
Displays time.
12-hour display
Clock Clock (Changes to service meter if
io 24-hour display
F4 is depressed.)
46 PC400, 450-8R
Switches
1. Buzzer cancel switch Auto-deceleration switch

2. Auto-deceleration switch The auto-deceleration switch toggles the auto-de-
3. Guidance icon celeration function on and off. When the working
4. Function switch mode is switched, it is automatically set to ON.
5. Working mode selector switch When it is set to ON, the auto-deceleration monitor
6. Travel speed selector switch appears.
7. Window washer switch a The auto-deceleration function does not work in
8. Wiper switch L mode.
9. Air conditioner control switch
Guidance icon and function switch
Buzzer cancel switch The function switches differ depending on the
Pressing this switch when the alarm buzzer is mak- screen display. Each guidance icon shows the func-
ing sound stops the alarm buzzer. tion of the switch below it.
If a new abnormality is detected, the alarm buzzer Switches with no guidance icon are disabled.
sounds. The functions shown by the guidance icons are as
Depending on the alarm buzzer type, it does not shown in the table below.
stop even if you press the buzzer cancel switch.
PC400, 450-8R 47
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F3 Select camera screen Selects camera screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
Selects item on left side (Selects right end

F3 Select item
item after left end item).
Selects item on right side (Selects left end
F4 Select item
item after right end item).
Selects item on lower side (Selects top item
F3 Select item after bottom item)/Resets holding of monitor-
ing.
Selects item on upper side (Selects bottom
F4 Select item
item after top item)/Holds monitoring.
Selects page on lower side (Selects top page
F1 Select item
after bottom page).
Selects page on upper side (Selects bottom
F2 Select item
page after top page).
F1 Display No. 1 camera screen Selects No. 1 camera screen.
Display No. 1 and No. 2 cam- Displays No. 1 and No. 2 camera screens
F4
era screens simultaneously.
Returns selected item to default setting.
F2 Return to default setting
(Used for adjustment of screen.)
Starts operation. (Used to start measurement
F1 Start of split fuel consumption on fuel consumption
display screen.)
Stops operation. (Used to stop measurement
F1 Stop of split fuel consumption on fuel consumption
display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
48 PC400, 450-8R
Working mode selector switch Travel speed selector switch

Pressing working mode selector switch (5) switches Each time you press the travel speed selector
among working modes. switch, the travel speed setting switches as shown
Check the working mode on the working mode mon- below.
itor. Lo o Mi o Hi o Lo ….
The travel speed setting is confirmable on the travel
speed monitor.
The relationship between the speed setting and the
monitor display is shown in the table below.
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
Crawler symbol + Hi High speed
Window washer switch

While the switch is being pressed, window washer
About B mode liquid is sprayed out. There is a time delay before
q When you try specifying B mode as a working the wiper starts.
mode, the buzzer sounds for safety's sake and
the following confirmation message appears. Wiper switch
Each time you press the wiper switch, the wiper set-
tings switch as follows.
OFF o INT o ON o OFF o ….
The wiper operation setting is confirmable on the
wiper monitor.
The relationship between the wiper setting and the
monitor display is shown in the table below.
Display Setting Wiper actuation status

Stowing stopped or now stow-
None OFF
ing
Wiper symbol +
INT Intermittent actuation
INT
Wiper symbol +
ON Continuous actuation
F5: Returns to the working mode selector screen. ON
F6: Specifies the breaker mode.
Air conditioner control switch
q If B mode is specified as a working mode when To operate the air conditioner, use the air condition-
you start the monitor, the buzzer sounds and the er control switches.
following message appears.
F5: Starts up in E mode.

F6: Starts up in B mode.
PC400, 450-8R 49
9a: Specifies airflow Camera screen display function

9b: Specifies temperature q For an optional-camera-equipped machine,
9c: AUTO pressing the F3 on the normal screen switches
9d: A/C to the camera image.
9e: Switches among air blowing modes q For a machine with no camera equipped, the
9f: Switches between inside air and outside air guidance icon for switching to the camera
9g: OFF screen does not appear; even if you press the
9a to 9c: Enables entered information simultane- switch, the screen does not switch to the camera
ously with switching to the air conditioner control image.
screen below. q Up to three cameras are mountable.
9d to 9f: Switches to the air conditioner control
screen below. Another pressing switches among
modes.
9g: Turns OFF the air conditioner function without
switching to the air conditioner screen.
F1: Displays the image of No. 1 camera full-screen.

F4: Displays the images of No. 1 and No. 2 cameras
at the same time.
F5: Returns to the normal screen.
If you do no operation at least 5 sec. with the air con-
ditioner control screen displayed, the window re- q Making operation of air conditioner button (1)
turns to the normal window. with the camera screen displayed may switch to
a When communication with the air conditioner is the air conditioner operation screen.
disconnected, or “spurting-out damper”, “A/M
damper”, or “refrigerant” has a problem, the
following screen appears.
50 PC400, 450-8R
F6, or no operation for 5 sec.: Returns to the camera

screen.
q Even when the camera screen is displayed, the

working mode selector switch, travel speed se-
lector switch, auto-deceleration switch, buzzer
cancel switch, wiper switch, and window washer
switch are enabled.
q Changing the working mode or travel speed re-
turns to the normal screen.
q If an abnormality corresponding to an alarm item
with the camera screen displayed, the alarm
monitor appears on the upper left of the screen.
If it appears, return to the normal screen with F5
to check the alarm display.
q If an abnormality corresponding to an error item
with the camera screen displayed, the error
monitor appears on the upper left of the screen.
If it appears, you must move the machine to safe
posture immediately and make inspections.
q If you do not operate the lever at least 10 sec. af-
ter the error monitor starts to blink, the screen
switches to the normal screen.
PC400, 450-8R 51
Service meter/time selector function

q Pressing F4 on the normal screen when the ser-
vice meter is displayed in the top center of the
screen switches the display to the time, and do-
ing so when the time is displayed switches the
display to the service meter.
52 PC400, 450-8R
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
F5: Cancels the reset to return to the maintenance

table screen.
F6: Resets the remaining time to return to the nor-
mal screen.
No operation at least 30 sec. : Returns to the normal
screen.
q The table below shows the maintenance items

and replacement intervals. The time remaining
to maintenance is reduced as the machine is op-
erated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 500
F1: Displays the next page. 04 Hydraulic filter 1000
Displays the top page when the last page is dis- 05 Hydraulic tank breather 500
played. 06 Corrosion resistor 1000(*)
F2: Displays the previous page. 07 Damper case oil 1000
Displays the last page when the top page is dis- 08 Final case oil 2000
09 Machinery case oil 1000
played.
10 Hydraulic oil 5000
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up. *: If equipped (To be determined)
F6: Switches to the maintenance time reset screen. q The content of the caution display differs accord-
No operation at least 30 sec. : Returns to the normal ing to the remaining time. The relationship is as
screen. shown in the table below.
q If the remaining time on the maintenance table Display Condition

Remaining time for mainte-
screen is less than 30 hours, the relevant items
None nance for all items is more than
are highlighted in yellow, and if 0 hours, they are 30 hours.
done in red. Notice display (black symbol There is one or more items with
q On the maintenance time reset screen, reset the displayed on yellow back- less than 30-hour remaining
remaining time for the selected item to return to ground) time for maintenance.
There is one or more items with
the default. Warning display (white symbol
less than 0-hour remaining time
q If switch F6 is not kept pressed for at least 1.5 displayed on red background)
for maintenance.
seconds, the switch operating sound can be
heard, but the screen does not switch to the
screen for resetting the remaining time.
PC400, 450-8R 53
q You can lock the maintenance time by a pass-

word to prevent it from carelessly being reset.
q The default password is “000000”.

q Enabling the password lock on an attach-
ment-equipped machine locks the breaker/at-
tachment setting screen at the same time.
a For information on changing the attach-
ment/maintenance password, see
“Attachment/maintenance password change
function” in the Testing and adjusting section.
54 PC400, 450-8R
User mode F3: Selects (highlights) an item one down.

q Pressing F6 on the normal screen enters the F4: Selects (highlights) an item one up.
user mode, switching to the user menu screen. F5: Cancels changes you made before confirming
q In user mode, you can specify items relating to them with F6 to return to the menu screen.
the machine monitor and machine shown below. F6: Moves to the setup items of the selected (high-
Breaker/attachment setting lighted) item.
Message display
Screen adjustment q Selecting B switches to the breaker setting
Time adjustment menu, and selecting ATT switches to the attach-
Language setting ment setting menu.
Economy mode adjustment q You can lock this menu with a password. En-
abling the password lock locks the maintenance
reset screen at the same time.

F4: Selects (highlights) an item one up.
F6: Switches to the setting screen for the selected Changing breaker mode setting
item. q Selecting B on the breaker/attachment setting
No operation at least 30 sec. : Returns to the normal screen switches to the breaker setting screen.
screen. On this screen, select the breaker setting selec-
(In user mode, no switch operation at least 30 sec. tion screen or breaker flow rate setting screen.
returns to the previous screen.)
Breaker/attachment setting
q For an attachment-equipped machine, this menu
allows you to adjust a flow rate in B mode and
ATT mode.
q For a machine with no attachment, this menu
does not appear.

F5: Returns to the breaker/attachment setting
screen.
F6: Switches to the setting screen for the selected
(highlighted) item.
PC400, 450-8R 55
1. Breaker setting selection screen. q On the flow rate level setting screen, change
q On this screen, you can allocate one of two the set flow rate.
set flow rates as a flow rate in breaker mode.
q The B symbol is displayed before items spec-
ified to breaker mode.
a The defaults of both flow rates are 300
l/min.
F3: Decreases the flow rate.

F4: Increases the flow rate.
F5: Returns to the flow rate setting screen
without changing the flow rate.
F6: Returns to the flow rate setting screen after
F3: Selects (highlights) an item one down. specifying the flow rate.
F4: Selects (highlights) an item one up. Flow level Flow rate (l/min) Remarks
F5: Returns to the breaker setting menu screen. 15 360
14 340
F6: Specifies the selected (highlighted) item as a
13 320
flow rate in breaker mode. 12 300 Default
11 280
2. Breaker flow rate setting screen 10 260
q On this screen, you can specify a flow rate. 9 240
8 220
q The B symbol is displayed before items spec-
7 200
ified to breaker mode.
6 180
5 160
4 140
3 120
2 100
1 80
Changing attachment mode setting

q Selecting ATT on the breaker/attachment setting
screen switches to the 2-way attachment setting
menu. On this screen, select the attachment set-
ting screen or breaker flow rate setting screen.

F5: Returns to the breaker setting menu screen.
F6: Switches to the flow rate level setting screen
for the selected (highlighted) item.
56 PC400, 450-8R
F3: Selects (highlights) an item one down. F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up. F4: Selects (highlights) an item one up.
F5: Returns to the breaker/attachment setting F5: Returns to the breaker setting menu screen.
screen. F6: Switches to the flow rate level setting screen
F6: Switches to the setting screen for the selected for the selected (highlighted) item.
(highlighted) item.
q On the flow rate level setting screen, change
1. Attachment setting selection screen the set flow rate.
q On this screen, you can allocate one of two
set flow rates as a flow rate in attachment
mode.
q The ATT symbol is displayed before items
specified to attachment mode.
a The defaults of both flow rates are 550
l/min.
F3: Decreases the flow rate.

F4: Increases the flow rate.
F5: Returns to the flow rate setting screen
without changing the flow rate.
F6: Returns to the flow rate setting screen after
specifying the flow rate.
F3: Selects (highlights) an item one down. Flow level Flow (l/min) Remarks
F4: Selects (highlights) an item one up. 8 550 Default
7 476
F5: Returns to the attachment setting menu.
6 401
F6: Specifies the selected (highlighted) item as a 5 327
flow rate in attachment mode. 4 253
q Selecting “No attachment” disables selec- 3 179
tion of attachment mode on the working 2 104
mode selection screen. 1 30
2. Attachment flow rate setting screen

q On this screen, you can specify a flow rate.
q The ATT symbol is displayed before items
specified to attachment mode.
PC400, 450-8R 57
Message display
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message monitor
appears on the upper left of the normal screen.
q The lighting green monitor indicates that there
are messages to be read.
q The lighting blue monitor appears when you
have not sent replies yet after opening messag-
es which accept replies.
q Messages will be deleted when their validity ex-

pire or a new message is received.
q When no message has not been received, “No
message” appears at the blue part of the top of
the screen.
q Separately from the message display for users
above, the service menu is provided with mes-
sage display for service.
Screen adjustment
q Press F6 to enter user mode and select q Selecting the Screen adjustment from the user
“Message display” and you can view (open) the menu and pressing F6 switches to the screen
messages. adjustment screen.
q From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
q When the light switch is in Night mode ON, the
night mode screen is adjustable.
q When the light switch is in Daytime mode ON or
OFF, the daytime mode screen is adjustable.
F6: Returns to the user mode screen.
q Under messages that accept replies, “Value to

be entered with 10-key: [ ]” appears.If it ap-
pears, enter the selected item number provided
in the message using the switches of the ma-
chine monitor, and press F6.
q “Do you want to transmit the entered value?” F2: Returns all adjusted values to the defaults.
appears under the message. Press F6 and the F3: Decreases the value indicated by the indicator
entered value will be sent. one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before confirming
them with F6 to return to the menu screen.
F6: Confirms the changes and moves to the next
item.
58 PC400, 450-8R
q For a camera-equipped machine, the bright- Clock adjustment

ness, contrast, and illuminance of the camera q Selecting the Clock adjustment from the user
screen are also adjustable. menu and pressing F6 switches to the clock ad-
q For a camera-equipped machine, selecting justment screen.
Screen adjustment from the user menu switches q On this screen, you can change the setting of the
to the screen for selecting a screen you want to time displayed on the normal screen.
adjust.
1) Time setting
F3: Selects (highlights) an item one down. Set the clock time. If the time setting item is
F4: Selects (highlights) an item one up. not highlighted, press F6 to highlight it.
F5: Cancels changes you made before confirming
them with F6 to return to the menu screen. The time display part is highlighted.
F6: Moves to the setup items of the selected (high- F3: Advances the clock one hour.
lighted) item. F4: Sets the clock back one hour.
F5: Cancels changes you made before
q The adjustment methods for the camera screen confirming them with F6 to return to the user
and normal screen are the same. menu.
q The background when adjusting the camera F6: Confirms the changes and moves to
screen is the No. 1 camera image. minute setting.
The minute display part is highlighted.

F3: Advances the clock one min.
F4: Set the clock back one min.
F5: Cancels changes you made before
confirming them with F6 to return to the use
menu.
F6: Confirms the changes and moves to the
12/24 display mode.
2) 12/24 display mode

Specify time display to 12-hour display
(AM/PM) or 24-hour display. If the item of
F3: Selects (highlights) an item one down. 12/24 display mode is not highlighted, press
F4: Selects (highlights) an item one up. F6 to highlight it.
F5: Cancels changes you made before confirming F3: Moves to the item one right.
them with F6 to return to the menu screen. F4: Moves to the item one left.
F6: Moves to the setup items of the selected (high- F5: Cancels the changes to return to the user
lighted) item. menu.
F6: Confirms the changes and moves to
summer time.
PC400, 450-8R 59
3) Summer time Economy mode adjustment

Selecting ON for this sets the time forward q Selecting the Economy mode adjustment from
one hour. Setting OFF returns to the ordinary the user menu and pressing F6 switches to the
time. Economy mode setting screen.
F3: Moves to the item one right. q From this menu, you can adjust engine output to
F4: Moves to the item one left. improve fuel consumption in E mode.
F5: Cancels changes you made before q The fuel consumption level is specified to one of
confirming them with F6 to return to the user four levels from E0 to E3. The larger the value,
menu screen. the better the fuel consumption, but the smaller
F6: Confirms the changes and moves to the the work rate.
time setting.
a Summer time (daylight saving time) is a

system to lead a life according to the
one-hour advanced time in order to make
efficient use of daylight time.
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage setting screen.
q From this menu, you can change the language to
be displayed on the monitor. Available languag-
es are as follows. F3: Selects (highlights) an item one down.
English, Japanese, Chinese, French, Spanish, F4: Selects (highlights) an item one up.
Portuguese, Italian, German, Russian, Turkish, F5: Cancels the changes to return to the user menu.
Indonesan, and Thai. F6: Cancels the changes to return to the user menu.

F5: Cancels the changes to return to the user menu.
F6: Cancels the changes to return to the user menu.
60 PC400, 450-8R
Idle stop guidance function

This function displays guidance to control unneces-
sary fuel consumption. It is displayed only when all
the following conditions are met.
q Energy saving guidance display of the service
menu is specified to ON.
q No operation is made at least 5 min. and the en-
gine is running at idle.
q No error or caution (excluding low hydraulic oil
temperature) is occurring.
This screen switches to the normal screen if one of

the following conditions occurs.
q When the lever is operated
q When F5 is pressed
q When an error or caution occurs
When you switch to the normal screen by pressing
F5, this screen does not appear even if the engine
continues to run at idle. If the engine continues to
run at least five min. after operating the lever, this
screen appears again.
PC400, 450-8R 61
Service meter check function Display LCD check function

q If you continuously pressing auto-deceleration q Continuously pressing the buzzer cancel switch
switch (1) and buzzer cancel switch (2) at the (1) and F2 at the same time on the password in-
same time when setting the starting switch to the put screen or normal screen causes the entire
OFF position, the service meter will appear on LCD to light in white. Release F2 and buzzer
the screen in 3 to 5 sec. cancel switch in order. If any part of the display
is black, the LCD is broken.
q When these switches are released, the LCD

goes out. q Pressing any function switch returns to the pre-
a Continuous operation of the machine monitor vious screen.
may display blue bright spots on this screen; it is
quite normal.
62 PC400, 450-8R
User code/failure code display function

q If there is any problem in machine operation, the
user code and failure code are displayed on the
monitor to advise the operator of the steps to
take.
q These codes appear on the normal screen.
q On the normal screen, user code (1) and failure
code (2) are displayed on the portion for the hy-
draulic oil temperature gauge.
q If multiple user codes or failure codes are issued,

they are displayed alternately every 2 sec. The
drawing below shows the case two types of user
codes and failure codes are displayed.
q If the telephone number has been set in the ser-

vice menu, the screen shows the telephone
symbol and telephone number simultaneously
with the user code/failure code. (For information
on how to input and set the telephone number,
see “Special functions of monitor panel” in the
Testing and adjusting section.)
PC400, 450-8R 63
Sensors
q The signals from the sensors are input to the When
Type of When
monitor panel directly. Sensor name abnorm
sensor normal
q Either side of a sensor of contact type is always al
connected to the chassis ground. Resis-
Coolant temperature — —
tance
When Resis-
Type of When Fuel level — —
Sensor name abnorm tance
sensor normal
al OFF
ON
ON Air cleaner clogging Contact (Closed
OFF (Open)
Hydraulic oil level Contact (Closed )
(Open)
)
Resis-
Hydraulic oil temperature — —
tance
Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
64 PC400, 450-8R
Hydraulic oil temperature sensor, coolant temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
PC400, 450-8R 65
Air cleaner clogging sensor
66 PC400, 450-8R
KOMTRAX system
q The KOMTRAX system consists of a KOMTRAX

terminal, communication antenna, machine
monitor, and GPS antenna.
q This system transmits various kinds of machine
information wirelessly. Persons to operate the
KOMTRAX can refer to the information at office
to provide various kinds of services for custom-
ers.
q Information transmittable from the KOMTRAX
system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
a To provide the services, you need to make an ar-
rangement for starting the KOMTRAX service
separately.
PC400, 450-8R 67
KOMTRAX terminal
TH300
q For japan / For other countries Outline

q Using satellite wave q This terminal sends various machine information
based on the network signals and input signals
1. Communication antenna connection obtained through the machine monitor, as well
2. Connector A (14 poles) as GPS position data, via wireless communica-
3. Connector B (10 poles) tion. This terminal can send information via com-
munication antenna.
q Corlditions of this terminal can be checked with
the "Display of KOMTRAX setting” in the service
mode of the machine monitor.
q This terminal cannot be used in the countries or
territories where it is not authorized by the law.
a When starting to use the KOMTRAX system or

changing the country where it is used, you are
required to notify the country where it will be
used in advance.
a When using the KOMTRAX system in Japan, the
terminal special to Japan must be mounted.
Input and output signals

Connector A Connector B
Pin No. Signal name Input/output Input/out-
Pin No. Signal name
A-1 Electric power supply Input put
A-2 NC(*1) — B-1 Serial signal DCD Output
A-3 NC(*1) — B-2 Serial signal RXD Output
A-4 Electric power supply switching Output B-3 Serial signal TXD Input
A-5 NC(*1) — B-4 Serial signal DTR Input
A-6 NC(*1) — B-5 Serial signal SGND Input
A-7 (GND) Input B-6 Serial signal DSR Output
A-8 (GND) Input B-7 NC(*1) —
A-9 NC(*1) — B-8 NC(*1) —
A-10 NC(*1) — B-9 NC(*1) —
A-11 NC(*1) — B-10 NC(*1) —
A-12 NC(*1) —
A-13 NC(*1) — *1: Never connect to NC or malfunctions or failures
A-14 NC(*1) — will occur.
*1:Never connect to NC or malfunctions or failures
will occur.
68 PC400, 450-8R
PC400, 450-8R 69
©2011 KOMATSU
All Rights Reserved
70
SEN04256-01
PC400, 450-8R
SEN04256-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
20 Standard value table

Standard service value table
Standard value table for engine related parts ............................................................................................. 2

Standard value table for chassis related parts ............................................................................................ 3
PC400, 450-8R 1
SEN04256-01 20 Standard value table
Standard value table for engine related parts

PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Engine SAA6D125E-5
Item Measurement conditions Unit Standard value Permissible value

High idle rpm 1,930 (+35/-15) 1,930 (+35/-15)
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 tempera-
All speed range (intake air temp: 20 °C) °C Max. 700 700
ture
%
Max. 40
At sudden acceleration (Low o High) {Bosch —
{Max. 4.0}
index}
Exhaust gas color Bosch
At rated output Max. 1.5 —
index
Bosch
At high idle Max. 1.0 —
index
Intake valve mm 0.33 —
Valve clearance Normal temperature
Exhaust valve mm 0.71 —
Engine oil temperature: 40 – 60 °C MPa
Compression pressure Min. 2.9 {Min. 30} 2.0 {20}
Engine speed: 200 – 250 rpm {kg/cm2}
At rated output kPa
Blow-by pressure Max. 1.47 {Max. 150} 2.94 {300}
Engine coolant temperature: Min. 70 °C {mmH2O}
At rated output SAE0W30EOS MPa 0.29 – 0.69
Engine oil tempera- SAE5W40EOS 0.18 {1.8}
ture: Min. 80 °C {kg/cm2} {3.0 – 7.0}
SAE10W30DH
Oil pressure
At low idle SAE15W40DH
MPa Min. 0.05
Engine oil tempera- SAE30DH 0.03 {0.3}
ture: Min. 80 °C engine oil {kg/cm2} {Min. 0.5}
Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Fan belt, alternator belt Deflection when pressed with finger
mm 13 – 16 13 – 16
tension force of approx. 98 N {10 kg}
2 PC400, 450-8R
Standard value table for chassis related parts

PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory
q Engine water temperature:
Within operating range
q Hydraulic oil temperature:
2 pumps at relief 1,930 ± 100 1,930 ± 100
q Engine at high idle
q Arm in relief condition
q Engine water temperature:
Engine speed

At 2-pump relief + q Hydraulic oil temperature:
rpm
one touch power Within operating range 1,830 ± 100 1,830 ± 100
up q Engine at high idle
q Arm relief + power max. switch in ON
condition
Speed when q Auto-deceleration switch in ON
auto-deceleration condition 1,300 ± 100 1,300 ± 100
is operated q All control levers in NEUTRAL
condition
Boom control
valve
Arm control valve
Spool stroke
Bucket control q Engine stopped

valve q For measuning point, see Control mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve.
valve
Travel control
valve
Boom control
85 ± 10 85 ± 10
lever
Travel of control levers
Arm control lever 85 ± 10 85 ± 10

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

Arm control lever
q Hydraulic oil temperature: {1.6 ± 0.4} {Max. 2.5}
Bucket control Within operation range 12.7 ± 2.9 Max. 21.6
lever q Engine at high idle {1.3 ± 0.3} {Max. 2.2}
q Hydraulic oil temperature: N {kg}
Swing control Within operating range 12.7 ± 2.9 Max. 21.6
lever q At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
q 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, 450-8R 3
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory
Within operation range
q Engine at high idle 4.2 ± 1.0 4.2 ± 1.0
Unload pressure
q Working mode: P mode {42 ± 10} {42 ± 10}
q Hydraulic pump output pressure with all
control levers in NEUTRAL position
34.81 +1.47/-0.98 33.34 – 36.77
(37.27 +1.47/-0.98) (35.79 – 39.23)
RAISE
{355 +15/-10 (380 {340 – 375 (365 –
+15/-10)} 400)}
Boom At low-
18.14 ± 0.98 16.67 – 19.61
pressure
LOWER {185 ± 10} {170 – 200}
setting
At high-
31.38 ± 1.47 29.2 – 33.34
pressure
{320 ± 15} {300 – 340}
setting
34.81 +1.47/-0.98 33.34 – 36.77
(37.27 +1.47/-0.98) (35.79 – 39.23)
Arm q Hydraulic oil temperature: {355 +15/-10 (380 {340 – 375 (365 –
Within operation range +15/-10)} 400)}
q Working mode: P mode 34.81 +1.47/-0.98 33.34 – 36.77
q Hydraulic pump output pressure with all (37.27 +1.47/-0.98) (35.79 – 39.23)
Bucket
measurement circuits relieved {355 +15/-10 (380 {340 – 375 (365 –
Hydraulic pressure
q Values inside parenthesis: Hydraulic oil +15/-10)} 400)}

pressure with power max. switch in ON
mode MPa 30.89 +1.47/-2.45 27.95 – 32.85
Swing
(reference only) {kg/cm2} {315 +15/-25} {285 – 335}
37.27 +2.94/-0.98 35.79 – 40.70

Travel
{380 +30/-10} {365 – 415}

Control circuit q Engine at high idle 3.24 ± 0.2 2.84 – 3.43
source pressure q Self pressure reducing valve output {33 ± 2} {29 – 35}
pressure with all control levers in
NEUTRAL position
q Hydraulic oil When all con-
temperature: Within trol levers in 4.2 ± 1.0 4.2 ± 1.0
operation range NEUTRAL {42 ± 10} {42 ± 10}
q Engine at high idle position
LS differential q Working mode: P
pressure mode
q Traveling speed: Hi When traveling
q Hydraulic oil pump 2.65 ± 0.1 2.65 ± 0.1
at half stroke
pressure – LS {27 ± 1} {27 ± 1}
(without load)
pressure
PPC valve Within operation range 2.9 +0.6/-0.2 2.9 +0.6/-0.2
output pressure q Engine at high idle {30 +5.5/-1.5} {30 +5.5/-1.5}
q Control lever full stroke
4 PC400, 450-8R
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory
q Bucket: Empty
Swing brake q Engine at high idle deg. PC400: Max. 120 PC400: Max. 150
angle q Working mode: P mode (mm) PC450: Max. 130 PC450: Max. 160
q Swing circle misalignment amount
when stopping after one turn
q For measuning posture, see Swing 1

Within operation range 90° 3.7 ± 0.4 Max. 4.6
q Bucket: Empty
Time taken to q Working mode: P mode
sec.
start swing q Time required for
passing points 90 and
180° from starting point
q For measuning posture, 180° 5.4 ± 0.5 Max. 6.4
see Swing 1

Swing
q Bucket: Empty
Time taken to q Engine at high idle
sec. 33.0 ± 3.3 Max. 38
swing q Working mode: P mode
q Time required for 5 more turns after
making initial one turn
q Hydraulic oil temperature: Within

operation range
q Engine stopped
q Keeping upper structure transverse on
Hydraulic drift of slope of 15°
mm 0 0
swing q Notching a mating mark on inner and
outer races of swing circle
q Mating mark misalignment amount
during 5 minutes

operation range
Leakage from q Engine at high idle
l/min Max. 5.5 Max. 11
swing motor q Swing lock switch: ON
q Leakage amount for one minute during
swing relief
PC400, 450-8R 5
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory
q Hydraulic oil temperature: STD: 63.2 ± 12.6 STD: 42.0 – 80.0

Lo
Within operation range LC: 67.3 ± 13.5 LC: 45.0 – 84.5
q Working mode: P mode
Travel speed q Time required for track STD: 45.1 ± 6.8 STD: 31.5 – 55.0
Mi sec.
(Idle travel) shoes to make 5 turns LC: 48.1 ± 7.2 LC: 34.0 – 58.0
after making one initial
idle turn
q For measuning posture, STD: 34.5 ± 35 STD: 28.0 – 41.5
see Travel 1 Hi
LC: 36.7 ± 3.6 LC: 32.0 – 44.0
Lo 24.0 ± 4.8 18.9 – 31.0

Travel speed q Flat ground
Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel) q Time required for
traveling 20 m after 10 m
trial run
q For measuning posture,
see Travel 2
Hi 13.1 – 1.3 11.7 – 15.1
Travel

operation range
q Engine at idle
q Travel speed: Lo
Travel deviation mm Max. 200 Max. 300
q Solid and flat ground
q Swerving amount while traveling 20 m
(X) after initial 10 m trial run.
q For measuning posture, see Travel 2
and 3

q Engine stopped
Hydraulic drift of
q Parking machine on slope 12° with mm 0 0
travel
sprocket facing upslope
q Sliding distance for 5 minutes
q For measuning posture, see Travel 4

Leakage of travel q Engine at high idle
l/min Max. 20 Max. 40
motor q Travel: Lock sprocket.
q Oil leakage amount for one minute with
traveling in relief condition
6 PC400, 450-8R
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory
Whole work
equipment PC400: Max. 600 PC400: Max. 900
(tooth tip fall PC450: Max. 700 PC450: Max. 1,050
amount) q Hydraulic oil temperature: Within
Hydraulic drift of work equipment
operation range
Boom q Flat and level ground
cylinder q Work equipment in measurement
PC400: Max. 25 PC400: Max. 38
(cylinder posture as illustrated above
PC450: Max. 29 PC450: Max. 44
retraction q Bucket load: 3,060 kg
amount) q Engine stopped
mm
q Work equipment control lever in
Arm cylinder
NEUTRAL position
(cylinder PC400: Max. 85 PC400: Max. 128
q Fall amount for 15 minutes as
extension PC450: Max. 100 PC450: Max. 150
measured every 5 minutes starting
amount)
immediately after initial setting
Bucket q For measuning posture, see Work
cylinder equipment 1
PC400: Max. 30 PC400: Max. 45
(cylinder
PC450: Max. 35 PC450: Max. 53
retraction
amount)
q Hydraulic oil
RAISE
temperature: PC400: 4.0 ± 0.4 PC400: Max. 4.8

Within operation range PC450: 4.2 ± 0.4 PC450: Max. 5.0
Work equipment

Boom
q Time required from raise
stroke end till bucket
LOWER
touches ground PC400: 2.9 ± 0.3 PC400: Max. 3.4

q For measuning posture, PC450: 2.8 ± 0.3 PC450: Max. 3.3
see Work equipment 2

Work equipment speed
CURL
Within operation range PC400: 4.3 ± 0.4 PC400: Max. 5.0

q Engine at high idle PC450: 4.7 ± 0.5 PC450: Max. 5.4
Arm q Time required from sec.
dumping stroke end to
digging stroke end
DUMP
q For measuning posture, 3.6 ± 0.4 Max. 4.3


CURL
Within operation range 3.6 ± 0.4 Max. 4.3

Bucket q Time required from
dumping stroke end to
digging stroke end
DUMP
q For measuning posture, 2.9 ± 0.3 Max. 3.5

PC400, 450-8R 7
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
gory

q Engine at low idle
Boom q Time required from raise stroke end till sec. Max. 3.0 Max. 3.6
bucket touches ground and pushes up
machine front
q For measuning posture, see Work
equipment 5
Time lag
q Time required from dumping stroke end PC400: Max. 3.0 PC400: Max. 3.6
Arm
till bucket stops momentarily after PC450: Max. 4.0 PC450: Max. 4.6
Work equipment
control lever is tilted to digging and

starts to move again
equipment 6
sec.
q Time required from dumping stroke end
Bucket Max. 3.0 Max. 5.0
till bucket stops momentarily after
control lever is tilted to digging and
starts to move again
equipment 7
q
Internal leakage
Hydraulic oil temperature:

Cylinders 4.5 20
cc/min
q Leakage amount for one minute with
Center cylinder or travel to be measured in
10 50
swivel joint relief condition

compound operation

Performance in
Swerving amount q Engine at high idle

in simultaneous q Working mode: P mode
mm Max. 400 Max. 440
operation of work q Traveling speed: Lo
equipment and q Flat and level ground
travel q Swerving amount (X) when traveling 20
m after initial trial run of 10 m
hydraulic pump
Performance of
Hydraulic pump
See next page l/min See next page
delivery
8 PC400, 450-8R
PC400, 400LC-8R
Applicable model
PC450, 450LC-8R
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Discharge amount of hydraulic pump (P mode)

Performance of hydraulic pump
q Pump speed: At 1,950 rpm, PC current 280 mA

Test pump Discharge Standard value Judgement
discharge pressure of other Average pressure for discharge standard lower
Check point pressure pump (MPa {kg/cm2}) amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (l/min) (l/min)
As desired P1 P2 (P1+P2)/2 See graph See graph
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, 450-8R 9
Posture of machine for measuring performance Travel 1: Travel speed (without load)
and measurement procedure
Control valve: spool stroke
Travel 2: Travel speed (actual run), travel deviation
Swing 1: Swing brake angle, time taken to start

swing, time taken to swing
Travel 3: Travel deviation
Swing 2: Hydraulic drift of swing
10 PC400, 450-8R
Travel 4: Hydraulic drift of travel Work equipment 3: Arm speed
Work equipment 1 : Hydraulic drift of work equip- Work equipment 4: Bucket speed
ment
Work equipment 5: Boom time lag

Work equipment 2: Boom speed
PC400, 450-8R 11
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
12 PC400, 450-8R
PC400, 450-8R 13
©2009 KOMATSU
All Rights Reserved
14
SEN04258-03
PC400, 450-8R
SEN04258-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up

Testing and adjusting, Part 1
Tools for testing, adjusting and troubleshooting.......................................................................................... 3

Sketches of special tools ............................................................................................................................ 7
Measuring engine speed............................................................................................................................. 8
Measuring air boost pressure ..................................................................................................................... 9
Measuring exhaust gas temperature .......................................................................................................... 10
Measuring exhaust gas color ...................................................................................................................... 11
Adjusting valve clearance ........................................................................................................................... 12
Measuring compression pressure............................................................................................................... 14
Measuring blow-by pressure....................................................................................................................... 16
Testing engine oil 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........................................................................................................................ 23
Checking fuel circuit for leakage ................................................................................................................. 27
Checking and adjusting fan belt and alternator belt.................................................................................... 28
Checking and adjusting air conditioner compressor belt tension................................................................ 29
PC400, 450-8R 1
SEN04258-03 30 Testing and adjusting
Measuring swing circle bearing clearance .................................................................................................. 30

Checking and adjusting track shoe tension................................................................................................. 31
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................................. 32
Measuring control circuit basic pressure..................................................................................................... 36
Checking and adjusting pump PC control circuit oil pressure ..................................................................... 37
Checking and adjusting pump LS control circuit oil pressure...................................................................... 40
Measuring solenoid valve output pressure.................................................................................................. 45
Measuring PPC valve output pressure........................................................................................................ 48
Adjusting play of work equipment and swing PPC valves........................................................................... 49
Inspecting locations of hydraulic drift of work equipment............................................................................ 50
Releasing residual pressure from hydraulic circuit...................................................................................... 52
Measuring oil leakage amount .................................................................................................................... 53
Bleeding air from various parts ................................................................................................................... 56
2 PC400, 450-8R
Tools for testing, adjusting and troubleshooting

Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
–101 – 200 kPa {–760 – 1, 500
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A mmHg}
sure (boost pressure)
799-401-2220 Hose 1
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 –99.9 – 1, 299°C
ature
Handy smoke
1 799-201-9001 1
Measuring exhaust gas checker
C
color Commercially
2 Smoke meter 1
available
Commercially
Adjusting valve clearance D Feeler gauge 1 (Intake: 35 mm, Exhaust: 57 mm)
available
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1420 Adapter 1
pressure 2
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5.0 kPa{ 0 – 500 mmH2O}
Pressure gauge: 2.5, 6.0, 40, 60
799-101-5002 Hydraulic tester 1
1 MPa {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres-
G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
sure
2 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 MPa {25, 60 ,400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring fuel pressure H 2 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Seal washer 1
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 f5 mm × 2 – 3 m
Measuring fuel return rate available
J Commercially
and leakage 4 Hose 1 f15 mm × 2 – 3 m
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
1 * Common with G1
Measuring and adjusting oil 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 K2
07002-11023 O-ring 2
PC400, 450-8R 3
1 * Common with G1
Measuring and adjusting oil 790-261-1204 Digital hydraulic tester 1
pressure in pump PC con- N
trol circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
1 * Common with G1
790-261-1204 Digital hydraulic tester 1
Measuring and adjusting oil
pressure in pump LS control O 799-101-5220 Nipple 4
2 * Common with M2
circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
1 * Common with G1
790-261-1204 Digital hydraulic tester 1
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
2 790-301-1730 Joint 1 Size: PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 q T-adapter 1 For Ne sensor
799-601-4150 q T-adapter 1 For oil pressure sensor
799-601-4211 q T-adapter 1 For controller (50-pole)
799-601-4240 q Socket 1 For ambient pressure sensor
Troubleshooting for/engine
S
controller/sensors/actuators 799-601-4250 q Socket 1 For Bkup sensor
799-601-4330 q Socket 1 For Bkup sensor
799-601-4350 q T-box 1 For 60-pole type
For coolant temperature sensor
795-799-5530 q T-adapter 1
For fuel temperature sensor
795-799-5540 q T-adapter 1 For boost temperature sensor
799-601-9020 q T-adapter 1 For injector
4 PC400, 450-8R
799-601-9420 q T-adapter 1 For common rail pressure sensor
799-601-9430 q T-adapter 1 For supply pump PCV
799-601-9000
or
Troubleshooting for/engine
S 799-601-9100 T-adapter assembly 1
controller/sensors/actuators
or
799-601-9300
799-601-9310 q Plate 1
For 24-pole type
799-601-9320 q T-box 1
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 q T-adapter box 1
799-601-2740 q Adapter for MIC 1
799-601-4100
or
799-601-4200
799-601-9000
or
799-601-9200
799-601-9020 q Adapter for DT 1
Troubleshooting for chas-
sis/sensors/wiring har- T 799-601-9030 q Adapter for DT 1
nesses 799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7010 q Adapter for X 1
799-601-7050 q Adapter for SWP 1
799-601-7080 q Adapter for M 1
799-601-7140 q Adapter for S 1
PC400, 450-8R 5
q Adapter for
799-601-7210 1
AMP040
q Adapter for
799-601-7220 1
AMP040
799-601-7360 q Adapter for relay 1
Troubleshooting for chas-
799-601-7370 q Adapter for relay 1
sis/sensors/wiring har- T
nesses 799-601-7500 T-adapter assembly 1
799-601-7520 q Adapter for 070 1
799-601-9000
799-601-9200
799-601-9030 q Adapter for DT 1
q Adapter for DT
799-601-9110 1
(GR)
799-601-9350 q Adapter for DRC 1
799-601-9360 q Adapter for DRC 1
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
1 21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
Socket
available Applicable engine serial No.:
Removal and installation of
560001 – 564999
engine coolant temperature ―
1 19 mm deep socket
sensor
(MITOLOY 4ML-19 or equivalent)
795T-981-1010 Socket
Applicable engine serial No.:
565000 and up
a For the model names and part Nos. of the T-adapters and boxed used for troubleshooting for the machine
monitor, controllers, sensors, actuators and wiring harnesses, see “Troubleshooting, List of T-boxes and
T-adapters”.
6 PC400, 450-8R
Sketches of special tools
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
PC400, 450-8R 7
Measuring engine speed 4) Measuring the engine speed when 2 pumps

are relieved and power maximizing is turned
1. Turn on the starter switch and then switch the on (near the rated speed):
machine monitor display to “Monitoring”.
1] Start the engine and set the fuel dial to the
a Fro the operating method of the machine
high idle (MAX) position.
monitor, see “Special functions of machine
2] Set the working mode switch to P-mode.
monitor”.
a Monitoring code: 01002 Engine speed 3] Put the arm in IN relief position and keep
01006 Engine speed the power max. switch depressed.
a Code 01002 represents the engine controller a The power maximizing function is re-
information and code 01006 represents the set automatically in about 8.5 seconds
pump controller information. Either of the even if the switch is being depressed.
codes is usable for the measurement. Thus measurement of the engine
a Engine speed is indicated in multiple of 1 speed must be completed within that
r/min (1 rpm). period.
5) Measuring the speed when the auto-deceler-
ator is in operation:
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 temper-

ature of the engine coolant and hydraulic oil rise
to the operating range.
3. Measure the engine speed under the respective

conditions listed below.
1) RPM at low idle:
low idle (MIN) position.
2) RPM at high idle:
3] Turn off the auto-deceleration switch.
3) Measuring the engine speed when 2-pumps
are relieved:
3] Put the arm in the IN relief position.
8 PC400, 450-8R
Measuring air boost pressure 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
799-201-2202 Boost gauge kit
A
799-401-2220 Hose the gauge and hose connection. Repeat op-
eration until the oil is drained out.
a Be careful not to touch any hot part of the engine a If Pm kit (A) is available, the air-bleeding cou-
when removing or installing the measurement pling (790-261-1130) in that kit may be used.
tools. a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
1. Open the inspection cover of the engine hood
and remove intake air measuring plug (1). 4. Start the engine and keep it running until temper-
a The plug removed can be any of the plug pro- ature of the engine coolant and hydraulic oil rise
vided on the right and left side. to the operating range.
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

measurement, and make sure that the machine
is back to normal condition.
PC400, 450-8R 9
Measuring exhaust gas temperature

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

2. Install sensor [1] of digital thermometer B and measurement, and make sure that the machine
connect it to meter [2]. is back to normal condition.
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 trou-

bleshooting
Measurement of the maximum exhaust temper-
ature must be done under actual working condi-
tions.
a PEAK mode of the digital thermometer shall
be used.
10 PC400, 450-8R
Measuring exhaust gas color

a Exhaust gas color measurement tools
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 re-
cording official data, use Smoke Meter C2.
2) Connect the probe hose, accelerator switch
1. Measurement with Handy Smoke Checker C1 outlet and air hose to the smoke meter C2.
1) Fit a filtering paper to Handy Smoke Checker a Keep the pressure of the supplied com-
C1. pressed air at 1.5 MPa {15 kg/cm2} or be-
2) Insert the exhaust gas intake port to exhaust low.
pipe (1). 3) Connect the power cable to an AC recep-
3) Start the engine and keep it running until the tacle.
engine coolant temperature rises to the oper- a Confirm that the smoke meter power
ating range. switch is in the OFF position, before con-
4) Start the engine and accelerate it suddenly or necting the power cable to an outlet.
run it at high idle and then operate the lever 4) Loosen the cap nut of the suction pump and
of smoke checker C1 in order to suction fit in the filter paper.
exhaust gas to the filter paper. a Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter C2 power switch to
the ON position.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Start the engine and keep it running until the
6) Remove the measurement tool after the
engine coolant temperature rises to the oper-
measurement, and make sure that the
ating range.
machine is back to normal condition.
7) Let the exhaust gas stay on the filtering paper
by depressing the accelerator pedal of
2. Measurement with Smoke Meter C2
Smoke Meter C2, when the engine speed is
1) Insert probe [1] of smoke meter C2, to the
suddenly accelerated or kept at high idle.
outlet of exhaust pipe (1) and fix it to the
8) Put the polluted filtering paper on
exhaust pipe with a clip.
non-polluted filtering paper (more than 10
sheets) in the filtering paper holder, and read
the indicated value.
PC400, 450-8R 11
Adjusting valve clearance

a Valve clearance adjustment tools
Commercially
D Feeler gauge
available

and remove the head cover (1) of every cylinder.
a As for No.1 and 2 cylinders, remove the air
intake connector on the head cover, too.
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 covers)

and then loosen the tension of the fan belt and
alternator belt.
a The belts are loosened for confirming the tim-
ing mark.
3. Remove radiator under cover.

6. Insert feeler gauge D in the clearance between
rocker arm (5) and crosshead (6) and adjust the
4. Rotate the crankshaft forward to bring the
valve clearance with adjustment screw (3).
stamped “1.6TOP” line (a) of the damper to
a With the feeler gauge being inserted, turn the
pointer (2) and set the No. 1 cylinder to the
adjustment screw until it allows the feeler
compression top dead center.
gauge to move slightly.
a Crank the crank shaft using the crank pulley
mounting bolt (Bolt width: 24 mm). In this
case, turn the bolt in the normal rotation to
prevent its loosening.
a When No. 1 cylinder is at the top dead center,
its rocker arm can be manually moved as
much as the valve clearance.If it cannot be
moved, that means that No. 1 cylinder is not
yet at the top dead center. In that case, rotate
it by one more turn.
12 PC400, 450-8R
7. While fixing adjustment screw (3), tighten

locknut (4).
3 Locknut: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the valve
clearance again.
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 “Testing
and adjusting fan belt and alternator belt
tension”.
PC400, 450-8R 13
Measuring compression pressure a Pass a wire, etc. under the fuel path project-
ed sideways and pull up the injector (Do not
a Compression pressure measurement tools 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 fail.
2. Open the inspection cover of the engine hood a Fix the adapter with the injector holder.
and remove the head cover (1) of the cylinder to 3 Holder mounting bolt:
be tested. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the con-
necting 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

injector wiring harness (4) and remove injector
(5).
a Before disconnecting the fuel high-pressure
tube, loosen all center clamps.
a Disconnect the terminal of the injector wiring
harness on the injector side and the bracket
on the rocker housing side and pull them out-
side the rocker arm housing (Loosen the 2
terminal nuts alternately).
14 PC400, 450-8R
7. Referencing “Special functions of machine 6) Alternately tighten 2 nuts at wiring harness

monitor”, set the cylinder cut-out. (15) end to injector (11).
k If the engine is not set in the cylinder 3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
cut-out, it will start and will be dangerous. 7) Tighten tube (18) to injector (11).
Accordingly, be sure to set the engine in 3 Sleeve nut:
this mode. 39.2 – 49.0 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel piping.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
8. Rotate the engine with the starting motor and

measure the compression pressure. 3 Rocker arm assembly mounting bolt:
a Read the pressure gauge pointer when it is 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
stabilized.
a Check the engine speed with the monitor. a Adjust the valve clearance. For details,
see “Adjusting valve clearance”.
9. After finishing testing, remove the testing tools
and return the removed parts. 3 Cylinder head cover mounting bolt:
a Install the injector, injector wiring harness, 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
and fuel high-pressure tube according to the
1) Install the O-ring and gasket to injector (11).
2) Fit holder (12) to injector (11) to temporarily
assemble them as a unit to the cylinder head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
2 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).
PC400, 450-8R 15
Measuring blow-by pressure

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

following conditions while setting the engine to
high idle.
q Working mode: P-mode
q Swing lock switch: ON (high pressure relief)
q Work equipment, swing and travel: Arm IN
relief position
a Read off the blow-by pressure value, when
the needle of the gauge steadies itself.

16 PC400, 450-8R
Testing engine oil pressure

a Testing tools for engine oil pressure
799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a The test point is subject to machine models.
1. Remove oil pressure pickup plug (1) from the

cylinder block.

and return the removed parts.
2. Connect nipple [1] of hydraulic tester F1 and

connect it to hydraulic tester F2.
3. Run the engine at the rated output and low idle

and test the oil pressure.
a When testing with the engine mounted on the
machine, test on the condition described in
the shop manual for the machine.
PC400, 450-8R 17
Handling fuel system parts Releasing residual pressure from

a Precautions for checking and maintaining fuel fuel system
system a Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) and high-pressure circuit of the fuel system while
consists of more precise parts than the conven- the engine is running.
tional fuel injection pump and nozzle. If foreign Low-pressure circuit: Between Feed pump –
matter enters this system, it can cause a trouble. Fuel filter – Fuel supply
When checking and maintaining the fuel system, pump
take care more than the past. If dust, etc. sticks High-pressure circuit: Between Fuel supply
to any part, wash that part thoroughly with clean pump – Common rail –
fuel. Fuel injector
a Precautions for replacing fuel filter cartridge a The pressure in both low-pressure circuit and
Be sure to use the Komatsu genuine fuel filter high-pressure circuit lowers to a safety level au-
cartridge. tomatically 30 seconds after the engine is
Since the common rail fuel injection system stopped.
(CRI) consists of more precise parts than the a Before checking the fuel system and installing
conventional fuel injection pump and nozzle, it and removing its parts, the residual pressure in
employs a high-efficiency special filter to prevent the fuel system must be released completely.
foreign matter from entering it. Accordingly, observe the following.
If a filter other than the genuine one is used, the k Before checking the fuel system, or installing
fuel system may have a trouble. Accordingly, or removing its parts, wait at least 30 sec-
never use such a filter. onds after stopping the engine until the re-
sidual pressure in the fuel system is
released. (Do not start the work just after
stopping the engine since there is residual
pressure.)
18 PC400, 450-8R
Measuring fuel pressure 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 range, it
Symbol Part No. Part name is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
H 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
Adapter
795-471-1450
3 (8 × 1.25 mm o R1/8)
07005-00812 Seal washer
a Test only the fuel pressure in the low-pressure

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

fuel filter head.
and return the removed parts.
2. Install nipple [1] of adapter H3 and hydraulic

tester H1 and connect them to hydraulic tester
H2.
PC400, 450-8R 19
Handling during cylinder cut-out Handling during no injection

operation cranking operation
a Reduced cylinder mode operation means to run a No-injection cranking means to crank the engine
the engine with the fuel injectors of 1 or more cyl- with the starting motor while all the injections are
inders disabled electrically to reduce the number stopped electrically. The purpose and effect of
of effective cylinders. The purposes and effects this operation are as follows.
of this operation are as follows. q Before the engine is started after it or the engine
1. This operation is used to find out a cylinder unit has been stored for a long period, the no-in-
which does not output power normally (or, jection cranking is performed to lubricate the en-
combustion in it is abnormal). gine parts and protect them from seizure.
2. When a cylinder is selected for the reduced a See the section of “Special functions of machine
cylinder mode operation, if the engine speed and monitor” when turning on the no injection crank-
output do not change from the normal operation ing 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
cylinder mode operation easily with switches to
find out a defective cylinder.
a See the section of “Special functions of ma-
chine monitor” when turning on the cylinder
cut-out operation.
20 PC400, 450-8R
Measuring fuel return rate and 2) Insert spacer J1 to return block (2) side and
leakage 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.
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
a Testing tools for leakage from pressure limiter testing the leakage from the pressure lim-
and return rate from injector iter.
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.
1. Preparation work
1) Remove tube (3) between common rail (1) 2. Testing leakage from pressure limiter
and return block (2). 1) Adjust routing to prevent its slacking of
inspection hose J3 and insert the hose end to
the oil pan (saucer).
2) Referencing “Measuring engine speed”, set
up the condition necessary for checking the
engine speed.
3) Start the engine and keep its speed to 1,600
rpm with no load.
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
Engine speed Leakage
(rpm) (cc/min)
1,600 Max. 10
PC400, 450-8R 21
5) After finishing testing, stop the engine.

4) Referencing “Measuring engine speed”, set
3. Testing return rate from injector up the condition necessary for checking the
a Keep the hose on the pressure limiter side engine speed.
connected and keep its end in the oil pan 5) Run the engine at the rated output.
while testing the return rate from the injector. 6) After making sure that the engine speed is
a Disconnect both ends of the injector. stabilized, measure return rate per minute by
1) Disconnect fuel return hose (4) of return use of measuring cylinder J5.
block (2). a You may test for 20 seconds and judge by
a Place a plug on the fuel hose side and multiplying the result by 3.
then fix it to the fuel tank. a If the supply pump is not supplying fuel,
Plug: 07376-70315 the engine speed may not rise. In this
case, record the engine speed, too, dur-
ing the test.
a If the return rate (spill) from the injector is
in the following range, it is normal.
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
2) Connect inspection hose J4 to return block

(2) side.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
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
tools and return the removed parts.
22 PC400, 450-8R
Bleeding air from fuel circuit 4. Turn electric priming pump switch (3) to the "ON"
position and release it.
a The switch returns automatically to original
Reference: The electric priming pump switch is in-
"N" position.
stalled to the chassis.
a Lamp (4) blinks and the electric priming
pump operates.
a Bleed air from the fuel circuit in the following cas-
es according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first time
after the fuel piping or supply pump is re-
placed
a If the fuel filter was replaced, do not fill the main

filter and prefilter with the fuel.
k While the fuel priming pump is in operation,

pressure is applied to the fuel circuit. Do not
loosen the air bleeding plug at this time,
since the fuel may spout out.
a This switch has a timer in it to start and stop
1. Turn the starting switch to the "OFF" position. the electric priming pump automatically (See
the figure).
2. Set valve (1) at the bottom of the fuel tank to a The electric priming pump stops while the
open position (0). lamp is blinking. This phenomenon is not ab-
normal, however.
a If the switch is turned to the "OFF" position
while the lamp is blinking, the lamp goes off
and the electric priming pump stops.
3. Open the left side inspection cover of the engine

and open air bleeding valve (2).
a Set the valve lever in horizontal position (b).
5. After the specified time (approx. 6.5 minutes),

lamp (3) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6. If the fuel was used up or the fuel piping or
supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (2) to the "ON" posi-
tion again after the electric priming pump stops
automatically.
7. When lamp (3) goes off, the air bleeding work is

completed.
PC400, 450-8R 23
8. Close air bleeding valve (2).

a Set the valve lever in vertical position (c).
9. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled au-
tomatically when the engine is rotated.
a If the engine does not start, the air in the
low-pressure circuit may have not been bled.
In this case, start the engine according to the
1) Turn the electric priming pump switch to the
"ON" position.
2) While the electric priming pump is operating,
start the engine.
a If the engine does not start, repeat the
above operation.
3) After the engine starts, keep it running for at
least 5 minutes to bleed all air from the fuel
circuit.
24 PC400, 450-8R
Reference: The manual priming pump (4) is installed to the engine.
a If fuel is used up or if a fuel circuit part is removed

and installed, bleed air from the fuel circuit ac-
cording 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 op-
erating priming pump (4).
a Do not add fuel to fuel main filter (2) external-
ly.
PC400, 450-8R 25
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 touches a Operate the priming pump until the fuel flows
the sealing face of the filter head, tighten the out of the air bleeder and tighten the air
fuel filter 3/4 turns. 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 au-
tomatically 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. After the packing of the pre-fuel filter touches the

sealing face of the filter head, tighten the fuel
filter 3/4 turns.
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 filter

(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}
26 PC400, 450-8R
Checking fuel circuit for leakage 8. Run the engine at high idle and load it.
a When testing the engine mounted on the ma-
k Very high pressure is generated in the
chine, stall the torque converter or relieve the
high-pressure circuit of the fuel system. If
oil pressure from the hydraulic pump.
fuel leaks while the engine is running, it is
dangerous since it can catch fire.
9. Inspect the fuel piping and devices for fuel
After testing the fuel system or removing its
leakage.
parts, test it for fuel leakage according to the
a Inspect mainly around the high-pressure cir-
cuit parts coated with the color checker for
a Clean and degrease the engine and the parts
fuel leakage.
around it in advance so that you can test it easily
a If any fuel leakage is detected, repair it and
for fuel leakage.
inspect again from step 1.
a If no fuel leakage is detected, inspection is
1. Spray color checker (developer) over the fuel
completed.
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

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

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

leakage.
fuel leakage.
PC400, 450-8R 27
Checking and adjusting fan belt 2. Loosen mounting bolt (3) and fixing bolt (4).
and alternator belt
3. Loosen locknut (5).
Checking
4. Slide alternator (7) by rotating adjusting nut (6),
1. Open the engine hood and remove the belt adjust V belt (8) tension and tighten locknut (5).
protection covers (2 covers). a Nut (6):
q Tightening the locknut clockwise moves it
2. Press the intermediate point of the belt between to the belt-loosening side.
fan pulley and compressor pulley with a finger q Tightening the locknut counterclockwise
and measure deflection (a) of the belt. moves it to the belt-tightening side.
a Deflection (a) when pressing force of approx. a Check the pulleys for breakage, V-groove for
58.8 kg {approx. 6 kg} is applied: wear, V-belt for wear and contact of the
Approx. 13 mm V-belt and V-groove for any trouble.
a A belt must be replaced with a new one when
it is elongated so as to eliminate the adjust-
ment allowance, or when cuts or cracks are
visible on it.
5. Tighten mounting bolt (3) and fixing bolt (4).

a When a V-belt is replaced, adjust the tension
again after operating the machine for an
hour.
Adjusting
a If the V belt deflection is abnormal, adjust it ac-
cording to the following procedure.

and remove the bracket (1) and cover (2).
28 PC400, 450-8R
Checking and adjusting air condi- 2. Loosen mounting bolt (2) and fixing bolt (3).
tioner compressor belt tension
3. Slide compressor (6) by loosening locknut (4)
and rotating adjusting nut, adjust V-belt (7)
Checking tension and tighten locknut (5).
1. Open the engine hood and remove the belt a Check the pulleys for breakage, V-groove for
protection covers (2 covers). 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 when
air compressor pulley and drive pulley with a it is elongated so as to eliminate the adjust-
finger and measure deflection (a) of the belt. ment allowance, or when cuts or cracks are
a Pressing force: Deflection (a) when pressing visible on it.
force of approx. 58.8 N {approx. 6 kg} is ap- 4. Tighten mounting bolt (2) and fixing bolt (3).
plied: 14 – 16 mm a When a V-belt is replaced, adjust the tension
again after operating the machine for an
hour.
Adjusting
a If the belt deflection is abnormal, adjust it accord-
ing to the following procedure.
and remove cover (1).
PC400, 450-8R 29
Measuring swing circle bearing 3. Set dial gauge to the zero point.
clearance
a Swing circle bearing clearance measurement
tools
Commercially
K Dial gauge
available
a Follow the steps explained below when measur-

ing 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 measurement.
1. Fix dial gauge K to outer lace (1) or inner lace (2) 4. Hold the arm nearly perpendicular to the ground,
of the swing circle and contact the probe against and lower the boom until the track shoes will be
the end face of inner lace (2) or outer lace (1) on lifted at the machine front.
the opposite side. a The upper structure is raised at the front and
a Set dial gauge K in the front side or rear side lowered at the rear at that time.
of the machine.
5. From this state, read the dial gauge K value.
a The value indicated by dial gauge K is the
clearance of the bearing.
2. Keep the work equipment in the max. reach

posture and keep the height of the bucket teeth
tip level with the lower height of the revolving
frame. 6. Return the machine to the condition of step 2
a The upper structure is lowered at the front and check that dial gauge K indicates zero point.
and raised at the rear at that time. a If zero value is not indicated, repeat the steps
in Items 3 through 5.
30 PC400, 450-8R
Checking and adjusting track Adjusting

shoe tension a If the track shoe tension is not proper, adjust it in
the following manner.
Checking 1. When the tension is too strong

1. Run the engine at low idle and drive the machine Loosen valve (3) to discharge the grease.
forward by the length of track on ground, and k Do not loosen the valve more than 1 turn.
then stop slowly. Otherwise, the valve may jump out be-
cause of the high-pressure grease inside.
2. Place steel bar [1] on the track shoe between the
idler (1) and the 1st carrier roller (2). 2. When the tension is too weak
a L beam is recommended for bar [1] because Add grease through valve (3).
of its deflection-free nature. a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
3. Measure maximum clearance (a) between steel chine slowly back and forth.
bar [1] and track shoe.
q Standard maximum clearance (a): 10 – 30
mm
PC400, 450-8R 31
Measuring and adjusting oil pres- 2) Fit nipple L2 and connect it to oil pressure
sure in work equipment, swing, gauge [1] of hydraulic tester L1.
a The oil pressure gauges used shall be
and travel circuits
58.8 MPa {600 kg/cm2}.
a Measuring and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equipment,
swing and travel
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
a The oil pressure in the work equipment, swing,

and travel circuits can be checked with monitor-
ing function of the monitor panel, too (For details,
see “Special functions of monitor panel”).
q Monitoring code: 01100 F pump pressure
01101 R pump pressure hydraulic oil pressure rises to the operating
q Pump oil pressure is indicated in multiples of 1
range.
MPa (1 kg/cm2, 1PSI).
Measuring
1. Preparation work
k Lower the work equipment to the ground
and, after stopping the engine, release re-
sidual pressure in the piping by operating
the control lever several times. Then loos-
en 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 mea-

suring plug
q (2): Rear pump discharge pressure mea-
suring plug
32 PC400, 450-8R
2. Combination of pump, actuator, and valve a Turning on the swing lock switch always
a When the oil from the pumps is divided, the turns on the 2-stage relief solenoid valve,
front pump and rear pump act independently causing the high-pressure relief. Accord-
on each actuator.Note that different actua- ingly, keep the swing lock switch turned
tors relieve different valves. OFF.
a When the work equipment circuit or swing cir-
cuit is relieved singly, the oil of the pumps is 5. Measurement of swing relief pressure
diverted. 1) Start the engine and move the swing lock
a The actuators in the table are arranged in the switch to the ON position.
order when the control valve is seen from the 2) Measure hydraulic oil pressure when the
front of the machine. engine is running at high idle and the swing
Pump Actuator Valve relieved circuit is relieved.
(F unload valve) (F main relief valve) a Hydraulic oil pressure when the swing
Service Safety valve for service motor safety valve is relieved is dis-
Boom Hi
played.
Arm Hi
F main relief valve a The relief pressure of the swing motor is
Front lower than the main relief pressure.
Bucket F main relief valve
Left travel F main relief valve
6. Measurement of travel circuit relief pressure
Raise: F main relief valve
Boom 1) Start the engine, and lock the travel.
Lower: Safety-suction valve
(Pump merge-divider valve) (Travel junction valve) k Insert pin [2] between the sprocket and
the track frame to positively lock the
(Self pressure reducing valve)
travel circuit.
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.
a Hydraulic oil pressure when the unload
valve unloads is displayed. 2) Measure the pressure when the engine is set
to high idle and the travel circuit is relieved.
4. Measurement of work equipment relief pres- a Hydraulic oil pressure with the main relief
sure valve in relief condition is displayed. In
1) Start the engine and move the cylinder to be the travel circuit relief, the pressure is
measured to its stroke end. high pressure relief all the time.
Adjusting
2) Measure hydraulic oil pressure when the
a Adjustment of the unload valve is not available.
cylinder is relieved while the engine is
running at high idle.
a The pressure measured when the main 1. Adjustment of main relief pressure
relief valve is relieved is indicated. a When the relief pressure of the work equip-
a If the power maximizing switch is re- ment circuit or travel circuit is abnormal, ad-
leased, the main relief valve is relieved at just main relief valves (3) and (4) according to
low pressure. If the former is pressed, the the following procedure.
q (3): Front main relief valve
latter is relieved at high pressure.
q (4): Rear main relief valve
a When adjusting the main relief valve on the
front pump side, remove the top cover of the
control valve.
PC400, 450-8R 33
a When adjusting the main relief valve on the 2. Adjustment of boom LOWER relief pressure (on
rear pump side, remove the under cover of the side where high pressure is set)
the control valve (when it is installed). a If the high relief pressure for boom LOWER is
a As for the main relief valve, be sure to adjust not normal, adjust the high pressure set side
its low-pressure relief pressure alone (adjust- of safety-suction valve (8) for boom LOWER
ing the low-pressure relief pressure automat- according to the following procedure.
ically sets the high-pressure relief pressure, a The the high-pressure relief pressure mode
too.). denotes the state in which the machine
a When the low-pressure relief pressure is push-up switch is turned on, disabling to ap-
turned on, the 2-stage relief valve is OFF and ply the pilot pressure to the switching port.
thus the pilot pressure is not applicable to the
switching port.
1) Disconnect pilot hose (9).

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

6) Check the pressure again after the adjust-
ment, following the aforementioned steps for
measurement.
34 PC400, 450-8R
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, ad-
ment, following the aforementioned steps for just safety valve (14) of the swing motor ac-
measurement. cording to the following procedure.
a Adjusting the high pressure set side
changes setting of the low pressure side.
Thus, this side requires adjustment, too.
3. Adjustment of boom LOWER relief pressure (on

the side where low pressure is set)
a When the low relief pressure for boom LOW-
ER is not normal or when the high pressure
set side was adjusted, adjust the low pres-
sure side of safety-suction valve (8) for boom
LOWER according to the following proce-
dure.
a The low-pressure relief pressure mode de-
notes the state in which the machine push-up
switch is turned off, disabling to apply the pi- 1) While fixing adjusting screw (15), loosen
lot 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 (13). pressure.
3) Turn holder (10) to adjust the pressure. a Adjustment screw:
a Turning the holder clockwise increases q Turning it clockwise increases the
the pressure. Turning it counterclockwise pressure.
decreases the pressure. q Turning it counterclockwise decreas-
a Quantity of adjustment per turn of holder: es the pressure.
Approx. 25.3 MPa {Approx. 258 kg/cm2} a Quantity of adjustment per turn of adjust-
4) While fixing holder (12), tighten locknut (13). ing screw:
3 Locknut: 78 – 93 Nm {8.0 – 9.5 kgm} 4.70 MPa {47.9 kg/cm2}
3) While fixing adjustment screw (15), tighten
locknut (16).
3 Locknut: 147 – 196 Nm {15 – 20 kgm}
5) Connect pilot hose (9).

6) Check the pressure again after the adjust-
measurement. 4) Check the pressure again after the adjust-
measurement.
PC400, 450-8R 35
Measuring control circuit basic 3. Start the engine and keep it running until the
pressure hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure inspection and adjust-
ment tools 4. Measure hydraulic oil pressure, when the engine
Symbol Part No. Part name is running at high idle and all the control levers
799-101-5002 Hydraulic tester are moved to the NEUTRAL position.
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the
oil filler cap gradually to release pressure in-
side the tank.
1. Remove the top cover of the control valve and

remove plug (1) for measuring the control circuit 5. Remove the measurement tool after the
basic pressure. measurement, and make sure that the machine
a The figure shows the control valve side is back to normal condition.
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 6.0
MPa {60 kg/cm2}.
36 PC400, 450-8R
Checking and adjusting pump PC 2) Install nipple N2 and connect it to oil pressure
control circuit oil pressure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauge with capacity
a Pump PC control circuit oil pressure checking
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 pres-
sure of the control circuit is normal.
ual pressure in the piping by operating the q The figure shows the PC valve output
control lever several times. Then loosen the side.
side the tank.
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.
pressure measuring plugs (1), (2), (3) and
(4).
q (1): Front pump discharge pressure mea
suring plug
suring plug 3) Start the engine and keep it running until the
q (3): Front PC valve output pressure mea- hydraulic oil temperature rises to the oper-
suring plug ating range.
q (4): Rear PC valve output pressure mea-
suring plug
PC400, 450-8R 37
4) Measure the pump discharge pressure and 2) Install nipple N2 and connect it to oil pressure
PC valve output pressure (pressure at servo gauge [1] of hydraulic tester N1.
piston inlet) at the same time after setting a The oil pressure gauges used shall be 6.0
following conditions with the engine running MPa {60 kg/cm2}.
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 pressure and PC
valve output pressure (servo piston
output pressure), the PC valve is normal.
Measured oil pres-
sure Oil pressure ratio
Pump discharge
pressure 1 3) Start the engine and keep it running until the
hydraulic oil temperature rises to the oper-
PC valve output Approx. 0.6 (Approx. ating range.
pressure 3/5)
a If there is any abnormality with PC valve

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

1) Open the pump room cover and remove
PC-EPC valve output measuring plug (5).
4) Measure the hydraulic oil pressure with all
the control levers kept in the NEUTRAL posi-
tion 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 fol-
lowing changes are observed.
Control
Engine Oil pressure
lever
2.94 MPa
Low idle
{30 kg/cm2}
Neutral
0 MPa
High idle
{0 kg/cm2}

38 PC400, 450-8R
Adjusting 3. Tighten locknut (8).

a If either of the following phenomena occurs and 3 Locknut: 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
the PC valve seems to be defective, adjust PC
valves (6) and (7) according to the procedure
shown below.
q As the working load increases, the engine
speed decreases remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (6): Front pump PC valve
q (7): Rear pump PC valve
a The width across flats of the PC valve locknut
is 13 mm and that of the adjustment screw
(inside width) is 4 mm.Do not turn any other
locknuts or adjustment screws since they af-
fects 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 position after turning it in reverse)
2. Turn adjustment screw (9) clockwise or counter-

clockwise to adjust.
a Adjustment screw:
q Turn it clockwise when the work equip-
ment speed is low (to increase pump ab-
sorption torque).
q Turn it counterclockwise when the engine
speed lowers (to decrease pump absorp-
tion torque).
a Following indicates the range of adjustment
available from the adjusting screw.
q Counterclockwise: Within 1 turn
q Clockwise: Within 1 turn
PC400, 450-8R 39
Checking and adjusting pump LS 2) Install nipple O2 and connect it to oil pressure
control circuit oil pressure gauge [1] of hydraulic tester O1.
a The oil pressure gauges used shall be 60
a Pump LS control circuit oil pressure checking
MPa {600 kg/cm2}.
and adjusting tools
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 making
sure that oil pressure of the work equipment,
swing, and travel circuits as well as basic pres-
sure of the control circuit is normal.
and, after stopping the engine, release resid- q The figure shows the LS valve output
ual pressure in the piping by operating the side.
side the tank.
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).
q (1): Front pump discharge pressuremea-
suring plug
3) Run the engine until the hydraulic oil temper-
suring plug
ature reaches the operating range and then
q (3): Front pump LS valve output pressure
push up the measurement side track shoe
measuring plug
with the work equipment.
q (4): Rear pump LS valve output pressure
q When measuring the front circuit: Left
measuring plug
track shoe
q When measuring the rear circuit: Right
track shoe
k Provide a working area of sufficient
space, as the raised track shoe will be
idly rotated.
40 PC400, 450-8R
2. Measurement of LS differential pressure

a LS differential pressure can be obtained by
measuring the pump discharge pressure and
LS pressure (actuator load pressure) at the
same time and computing the difference be-
tween the two pressures.
pressure measuring plugs (1), (2), (5) and
(6).
q (1): Front pump discharge pressure mea-
suring plug
suring 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.
q Work equipment, swing and travel: 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, pay-
ing enough attention to the surroundings
for safety.
a Testing cindition and judgment method:
When the hydraulic pressures are within q (5): Front pump LS pressure measuring
ratio in the table, LS valve is normal plug
Position of levers
q (6): Rear pump LS pressure measuring
Travel lever plug
All levers and at moved halfway
neutral (Travel without
load)
Pump dis-
sure to be mea-
Hydraulic pres-
1 (Actual value
charge pres-
is set as 1)
sure Almost same
sured
pressure
LS valve pat- Apprax, 3/5 of
pressure pressure above

2) Install nipple O2 and connect it to the oil pres-
sure gauge of differential pressure gauge O3
or hydraulic tester O1.
a When using differential pressure gauge:
Connect the pump discharge pressure to
the high pressure side (back side) and LS
pressure to the low pressure side (bottom
side).
The differential pressure gauge needs 12
DCV power. Thus connect a battery to it.
PC400, 450-8R 41
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/cm2} at maximum. Thus
measure the pressure reconnecting the
same gauge.
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
q Work equipment, swing and travel: When
all levers are at neutral and when travel
lever is at half stroke (one side of travel is
q The figure shows the LS pressure side. at idle)
a Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
a Calculating LS differential pressure
(When the oil pressure gauge is used):
LS differential pressure = Pump
discharge pressure – LS pressure
a If LS differential pressure is in the follow-
ing conditions, it is judged normal.
LS differential
Operation of levers
pressure
Unload pressure
When all levers at neutral (See “Standard
value table”)
Maximum LS dif-
3) Run the engine until the hydraulic oil temper- Travel lever moved half- ferential pressure
ature reaches the operating range and then way (Travel at idle) (See “Standard
push up the measurement side track shoe value table”)
with the work equipment. 5) Remove the measurement tool after the
q When measuring the front circuit: Left
track shoe machine is back to normal condition.
q When measuring the rear circuit: Right
track shoe
k Provide a working area of sufficient
space, as the raised track shoe will be
idly rotated.
42 PC400, 450-8R
3. Measurement of LS-EPC valve output pressure 4) Measure the oil pressure when the engine is
1) Open the pump room cover and remove running at high idle and the travel speed
LS-EPC valve output measuring plug (7). switch and travel control lever are operated.
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 pressure
switch is turned ON (Stop the operation
short of starting the machine).
2) Install nipple O2 and connect it to oil pressure 5) Remove the measurement tool after the
gauge [1] of hydraulic tester O1. measurement, and make sure that the
a Use the oil pressure gauge with capacity machine is back to normal condition.
6.0 MPa {60 kg/cm2}.

ating range.
PC400, 450-8R 43
Adjusting
a If the LS differential pressure is abnormal, adjust
LS valves (8) and (9) according to the following
procedure.
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. While fixing adjusting screw (10), loosen locknut

(11).
2. Turn adjusting screw (10) to adjust the pressure.

a Adjustment screw
q Turned to the right, the differential pres-
sure is increased.
q Turned to the left, the differential pressure
is decreased.
a Quantity of adjustment per turn of adjustment
screw (LS differential pressure):
1.3 MPa {13.3 kg/cm2}
3. After the adjustment, confirm that LS differential

pressure is normal, following the steps for
measurement explained earlier.
44 PC400, 450-8R
Measuring solenoid valve output 2. Install adapter P2 or P3 and connect the

pressure currently disconnected hose again.
a Solenoid valve output pressure measurement 3. Install nipple [1] of hydraulic tester P1 and
tools connect it to oil pressure gauge [2].
Symbol Part No. Part name a Use the oil pressure gauge with capacity 5.9
1
799-101-5002 Hydraulic tester MPa {60 kg/cm2}.
790-261-1204 Digital hydraulic tester a Figure shows the outlet hose of the 2-stage
799-401-3100 Adapter (Size 02) solenoid valve being installed with the mea-
P 2 suring tool.
02896-11008 O-ring
799-401-3200 Adapter (Size 03)
3
02896-11009 O-ring
a Measure the solenoid valve output pressure af-

ter confirming that the control circuit source pres-
sure is normal.
side the tank.
1. Remove the control valve top cover and discon- 4. Start the engine and keep it running until the
nect outlet hoses (1) to (7) of the target solenoid hydraulic oil temperature rises to the operating
valve of measurement. range.
a A quick coupler is attached to the solenoid
valve of PPC lock solenoid valve's outlet
hose. Thus, measurement shall be conduct-
ed 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
7 PPC lock solenoid valve
5. Run the engine at high idle and operate the
control levers and switches to turn the solenoid
valve ON or OFF. Measure the oil pressure
when the valve is turned on and also when
turned off.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing “Table
for functioning conditions” for each solenoid
valve.
a The operating condition of the solenoid valve
can be checked with the monitoring function
of the machine monitor (For the operating
procedure, see “Special functions of ma-
chine monitor”.
PC400, 450-8R 45
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 pressure
as the control circuit basic
ON (Energized)
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
46 PC400, 450-8R
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
Travel speed switch is at Mi or F or R pump pressure is at 32.3 MPa {330 kg/cm2} 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
F or R pump pressure is at 19.6 MPa {200
When a L-mode is not kg/cm2} or above
Work equip- selected F or R pump pressure is at 14.7 MPa {150
Travel single signal ment, swing, OFF
is ON kg/cm2} or below
and service
singles are ON
ON kg/cm2} or above
When L mode is selected
OFF
kg/cm2} or below
Arm IN and bucket CURL F or R pump pressure is at 24.5 MPa {250
ON
Travel signal is Swing sig- PPC pressure are 1.9 kg/cm2} or above
OFF nal is OFF MPa {19.5 kg/cm2} or F or R pump pressure is at 19.6 MPa {200
above kg/cm2} 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} or ON
Travel steering signal is OFF ated singly 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
PC400, 450-8R 47
Measuring PPC valve output

pressure
a PPC valve output pressure measurement tools
1
Q 790-261-1204 Digital hydraulic tester
2 790-301-1730 Joint (PF1/4 + PT1/4)

side 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 in-
2. Remove PPC hydraulic switch or PPC pressure stallation position.
sensors (1) to (10) of the target circuit of a The oil pressure gauges used shall be 6.0
measurement. MPa {60 kg/cm2}.
a PPC pressure sensor for arm IN and bucket a Figure shows the measuring tools being in-
CURL detects errors in the electrical system stalled at the installation position of PPC
as the starter switch is turned on when the pressure sensor for arm IN circuit.
connector is disconnected. After removing
the pressure sensor, connect it to the con-
nector again and then clamp it to a nearby
bracket.
Circuit to be mea- Circuit to be mea-
No. No.
sured sured
Boom RAISE Bucket DUMP
1 6
(S06) (S05)
Boom LOWER
2 7 Swing LEFT (S07)
(S02)
Swing RIGHT
3 Arm IN (S04) 8
(S03)
4 Arm OUT (S08) 9 Travel (S30)
Bucket CURL
5 10 Steering (S31)
(S01)
4. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
48 PC400, 450-8R
5. Measure the pressure when the engine is Adjusting play of work equipment
running at high idle and the control lever of the and swing PPC valves
circuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If there is excessive play in the work equipment
a If PPC valve output pressure is at the level or swing lever, adjust it in the following manner.
shown below, it is judged normal.
1. Remove work the equipment and swing PPC
Operation of levers Oil pressure
valve assembly.
Neutral 0 MPa {0 kg/cm2}
2. Remove boot (1).
Almost the same pressure
as the control circuit basic
Stroke end 3. Loosen locknut (2) and push disc (3) into piston
pressure (See “Standard
values table”) (4) until it touches the heads of 4 pistons (4).
a Do not move the piston while doing this work.
4. Keep disc (3) in place and tighten locknut (2) to
the specified tightening torque.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5. Install boot (1).
6. Install the work equipment and swing PPC valve

assembly.
PC400, 450-8R 49
Inspecting locations of hydraulic 2. Inspection of arm cylinder

drift of work equipment 1) Stop the arm cylinder at a position approxi-
mately 100 mm in front of the IN stroke end
a If hydraulic drift occurred on the work equipment and then stop the engine.
(cylinder), check to see if the cause is on the cyl-
inder packing side or control valve side accord-
1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
a Fill the bucket with earth or apply the rat-
ed load to the bucket.
2) Operation the arm control lever in the IN posi-

tion
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.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
2) When inspecting the boom cylinder, shift the seconds to charge the accumulator
boom control lever to RAISE side and when again.
inspecting the bucket cylinder, shift the
bucket control lever to CURL side. [Reference] Reasons why the lowering speed is
q If, as the result, drifting speed increases, increased by the above operation when the
failure on the cylinder packing should be cylinder packing is the cause of the hydraulic
suspected. drift:
q If the speed remains unchanged, failure 1) If the work equipment is set to the above
on the control valve should be suspected. posture (holding pressure applied to the
a Operate the control lever with the engine bottom end), the oil at the bottom end leaks
starting switch in the ON position. to the head end. However, the volume at the
a If pressure in the accumulator has head end is small than the volume at the
dropped, run the engine for approx. 10 bottom end by the volume of the rod end, so
seconds to charge the accumulator the internal pressure at the head end
again. increases because of the oil flowing in from
the bottom end.
2) If the internal pressure of the head end
increases, the pressure at the bottom end
also rises in proportion to this and balanced
at certain level (this level depends on the
volume of leakage). As the pressure is
balanced, the drifting speed is decreased.
50 PC400, 450-8R
3) If the lever is then operated according to the

procedure given above, the circuit at the
head end is opened to the drain circuit (the
bottom end is closed by the check valve), so
the oil at the head end flows to the drain
circuit and the downward movement
becomes faster.
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 differ-
ence in the hydraulic drift volume, the PPC
valve is defective (internal failure).
PC400, 450-8R 51
Releasing residual pressure from 3. Releasing residual pressure from swing motor
hydraulic circuit circuit
a The residual pressure in the swing motor cir-
1. Releasing residual pressure from hydraulic tank cuit can be released by performing the same
k Since the hydraulic tank is enclosed and operation for “Releasing residual pressure
pressurized, release the residual pres- from hydraulic cylinder circuit” (Operate the
sure from it when removing a hose or a lever in the swing direction only, however).
plug connected to it.
1) Lower the work equipment to the ground in a 4. Releasing residual pressure from travel motor
stable position and stop the engine. circuit
2) Loosen oil filler cap (1) of the hydraulic tank a Since the control valve spool of the travel mo-
gradually to release the air in the tank. tor circuit is open, the pressure in this circuit
can be released by performing the same op-
eration as that for “Releasing residual pres-
sure from hydraulic tank”.
2. Releasing residual pressure from hydraulic

cylinder circuit
k When disconnecting a pipe between a hy-
draulic cylinder and the control valve, re-
lease the residual pressure from the
piping according to the following proce-
dure.
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 pres-
sure stored in the accumulator. This pres-
sure 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.
k 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.
52 PC400, 450-8R
Measuring oil leakage amount

a Measuring tools for oil leakage k Release the residual pressure from the
Symbol Part No. Part name piping on the arm cylinder head side.
Commercially For details, see “Releasing residual
R Measuring cylinder pressure from hydraulic circuit” (Op-
available
erate the lever in the arm IN direction
only, however).
1. Measuring oil leakage from boom cylinder
3) Disconnect hose (2) on the cylinder head end
1) Start the engine and keep it running until the and block the hose end with a plate.
k Be careful not to disconnect the hose
ating range. at the cylinder bottom end.
2) Move the boom cylinder to the RAISE stroke a Use the following parts to block the hose
end and stop the engine. side.
k Release the residual pressure from the 07379-01044 (Flange #10)
piping on the boom cylinder head side.
For details, see “Releasing residual
pressure from hydraulic circuit”. (Op-
erate the lever in the boom RAISE di-
rection only, however).
3) Disconnect hose (1) on the cylinder head end
and block the hose end with a plate.
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
3. Measurement of oil leakage amount from bucket

cylinder
boom circuit by raising the boom.
k Take care not to “lower the boom”.
ating range.
2) Move the bucket cylinder to the CURL stroke
end and stop the engine.
k Release the residual pressure from the
minute.
piping on the bucket cylinder head
6) After the measurement, make sure that the side. For details, see “Releasing resid-
machine is back to normal condition. ual pressure from hydraulic circuit”
(Operate the lever in the bucket CURL
2. Measurement of oil leakage amount from arm direction only, however).
cylinder
3) Disconnect hose (3) on the cylinder head
1) Start the engine and keep it running until the side and block the hose side with a plate.
ating range. at the cylinder bottom end.
2) Move the arm cylinder to the IN stroke end
and stop the engine.
PC400, 450-8R 53
a Use the following parts to block the hose a Continue this condition for 30 seconds,
side. then measure the oil leakage amount for
07379-01044 (Flange #10) one minute.
a After measurement 1 time, swinging 180
°, and then measure again.
5. Measurement of oil leakage amount from travel

motor
1) Take off the travel motor cover.
2) Run the engine until the hydraulic oil is
heated up to the operating range and then
lock the travel lever to stop the engine.
k Insert pin [1] between the sprocket and
the track frame to positively lock the
travel circuit.
bucket circuit by curling the bucket.
k Take care not to “Dump the bucket”.
minute.
4. Measurement of oil leakage amount from swing

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

4) Run the engine at high idle, relieve the swing
circuit, and measure the oil leakage.
54 PC400, 450-8R
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 seconds,
then measure the oil leakage amount for
one minute.
a Measure several times, moving the motor
a little (changing the position of the valve
plate and cylinder and that of the cylinder
and piston) each time.
PC400, 450-8R 55
Bleeding air from various parts

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
pump work
q Replacing hydraulic oil q q
q q q q
q Cleaning strainer (See note) (See note)
q Replacing return filter element q o o o q
q Replacing and repairing hy-
draulic pump q q q o o q
q Removing suction piping
q Replacing and repairing con-
trol valve q q o o q
Contents of work
q Removing control valve piping

q Replacing and repairing cylin-
der q q o o q
q Removing cylinder piping
q Replacing and repairing swing
motor q o q o q
q Removing swing motor piping
q Replacing and repairing travel
motor q o o q q
q Removing travel motor piping
q Replacing and repairing swivel
joint q o o o q
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 posi-
tion higher than the oil level in the hydrau-
lic 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
7.8 – 9.8 Nm {0.8 – 1.0 kgm} When running the engine after performing step
a When the drain hose was disconnected 1, keep its speed at low idle for 10 minutes.
for above operation, connect it again after a If the engine coolant temperature is low and
tightening the bleeder. the automatic warm-up operation is started,
stop the engine temporarily and reset the au-
tomatic warm-up operation with the fuel con-
trol dial (Set the starting switch in the ON
position and hold the fuel control dial in the
MAX position for 3 seconds, and the auto-
matic warm-up operation is reset).
56 PC400, 450-8R
3. Bleeding air from hydraulic cylinder 5. Bleeding air from travel motor
a In case a cylinder is replaced with new one, it 1) Take off the travel motor cover.
is advised to bleed air from the new one be- 2) Start the engine and run it at low idle.
fore mounting the work equipment.It is espe- 3) Loosen bleeder (4) to make sure oil oozes
cially so with the boom cylinder, because its out.
rod does not extend to the stroke end of
4) After making sure that the oil from bleeder (4)
LOWER side, after the work equipment is
is free from mixed air, tighten the bleeder.
3 Air bleeder:
mounted.
1) Start the engine and keep running at low idle 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
for 5 minutes.
2) Raise and lower the boom 4 to 5 times with
the engine running at low idle.
a Stop the piston approximately 100 mm in
front of the stroke end so that it may not
be relieved.
3) While running the engine at high idle,
perform step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end and relieve
the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor 5) Using the work equipment, lift the track shoe
1) Start the engine and run it at low idle. of one side.
2) Loosen S port hose (3) gradually to make 6) Gradually run the lifted track shoe at idle for
sure oil oozes out through the S port hose. approximately two minutes.
k In this case, don't try to turn on the
a Repeat the same for the opposite side
swing operation. track shoe.
3) When oil does not flow out, stop the engine
once, disconnect S port hose and then fill up
the motor case with oil.
a As the motor case is filled up with oil, con-
nect 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 opera-
tion in left and right directions at slow speeds.
PC400, 450-8R 57
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, and stop the
engine.
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 situated
between H and L lines.
a If the oil level is below line L, it is insuffi-
cient. Add oil.
58 PC400, 450-8R
PC400, 450-8R 59
©2011 KOMATSU
All Rights Reserved
60
SEN04259-03
PC400, 450-8R
SEN04259-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up

Special functions of machine monitor ......................................................................................................... 2
PC400, 450-8R 1
Special functions of machine monitor

Air conditioner specification
2 PC400, 450-8R
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery. In
this case, the machine monitor goes off for a mo-
ment. This phenomenon is not a failure, howev-
er.
Upper section of machine monitor (Switch sec-
tion)
[F1]: F1 function switch
a The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.
a If the graphic mark of a function switch is not dis-
played, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-decelerator switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed shifting
Heaterless specification switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or heater
switch
switch
switch
switch
Switch having no numerals: Air conditioner or heat-
er switch
a Each switch has the function indicated by graph-
ic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of
multi-display.
a The difference between the air conditioner spec-
ification, heater specification, and heaterless
specification is only the functions of the switches
in this section.
PC400, 450-8R 3
tOrdinary 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 according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
t Operator mode (Outline) Service mode
6p 20p
A Display of KOMATSU logo 6p Monitoring 21p
A Display of inputting password 7p Mechanical Systems 25p
A Display of check of breaker mode 7p Abnormality Electrical Systems 26p
Record Air-conditioning System/Heater
A Display of check before starting 7p 31p
System
A Display of warning after check before starting 8p Maintenance Record 32p
A Display of ending of maintenance interval 8p Maintenance Mode Change 33p
Display of check of working mode and travel
A 8p Phone Number Entry 35p
speed
A Display of ordinary screen 8p Key-on Mode 36p
A Display of end screen 9p Unit 37p
B Selection of auto-deceleration 9p With/Without Attachment 38p
Attachment/Maintenance Pass-
B Selection of working mode 9p Default 39p
O (Special operation)
word
B Selection of travel speed 10p Camera 40p
B Operation to stop alarm buzzer 10p ECO Display 41p
B Operation of windshield wiper 11p Breaker Detect 42p
B Operation of window washer 11p Pump Absorption Torque 43p
B Operation of air conditioner/heater 11p Low Speed 44p
Adjustment
Operation to display camera mode (if camera
B 12p Attachment Flow Adjustment 45p
is installed)
B Operation to display clock and service meter 12p Cylinder Cut-Out 46p
B Check of maintenance information 13p No Injection 47p
Setting and display of user mode
B 13p Fuel Consumption 49p
(Including KOMTRAX messages for user)
C Display of energy-saving guidance 14p Terminal Status 50p
C Display of caution monitor 14p KOMTRAX GPS & Communication Status 51p
C Display of automatic judgment of breaker 15p Settings MODEM S/N (TH300) 52p
C Display of user code and failure code 15p MODEM IP Address (TH200) 53p
O (Special operation) Display of KOMTRAX message 54p
Function of checking display of LCD (Liquid
D 17p
Crystal Display)
D Function of checking service meter 17p
Function of changing attachment/maintenance
D 18p
password
4 PC400, 450-8R
a Classification of operator mode

A: Display/Function from time when starting switch is turned ON to time when screen changes to ordi-
nary screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch
PC400, 450-8R 5
t Operator mode (Outline) a Display pattern of operator mode

a Only outline of the operator mode is described in The contents of display from the time when
this section. For details of contents/operation of starting switch is turned ON to time when screen
each function/display, see the Structure, func- changes to ordinary screen depends on the
tion and maintenance standard, or Operation setting and condition of the machine.
and Maintenance Manual. A: When engine start lock is set effective
a The following are the displays or functions of the B: When engine start lock is set ineffective
operator mode explained in this section (includ- C: When working mode at start is set to breaker
ing some items which need special operations). mode (B)
Display pattern D: When there is abnormal item in
A B C D E check-before-starting items
Display of KOMATSU logo 1 1 1 1 1 E: When there is maintenance item which is not
Display of inputting password 2 — — — — maintained after specified interval
Display of check of breaker mode — — 2 — —
Display of check before starting 3 2 3 2 2
Display of warning after check before Display of KOMATSU logo
— — — 3 — When the starting switch is turned ON, the KOMAT-
starting
Display of ending of maintenance SU logo is displayed for 2 seconds.
— — — — 3
interval a After the KOMATSU logo is displayed for 2 sec-
Display of check of working mode onds, the screen changes to “Display of input-
4 3 4 4 4
and travel speed ting password”, “Display of check of breaker
Display of ordinary screen 5 4 5 5 5 mode (if B mode is set)”, or “Display of check
Display of end screen
before starting”.
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Operation to stop alarm buzzer
Operation of windshield wiper
Operation of windshield washer
Operation of air conditioner/heater
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode
(including KOMTRAX messages for user)
Display of energy-saving guidance
Display of caution monitor
Display of automatic judgment of breaker
Display of user code and failure code a The following screen may be displayed instead
O (Special operation) of the above Display of inputting password
Function of checking display of LCD (Liquid Crystal screen.
Display) a If this screen is displayed, call the person re-
Function of checking service meter sponsible to operation of KOMTRAX in your Ko-
Function of changing attachment/maintenance pass-
matsu distributor and ask for remedy.
word
6 PC400, 450-8R
Display of inputting password

After the KOMATSU logo is displayed, the screen to
input the engine start lock password is displayed.
a This screen is displayed only when the engine
start lock function is set effective.
a If the password is input normally, the screen
changes to “Display of check of breaker mode
(if B mode is set)” or “Display of check before
starting”.
a The machine monitor has some password func-
tions other than the engine start lock. Those
functions are independent from one another.
Display of check before starting

When the screen changes to the check-before-start-
ing screen, the check before starting is carried out
for 2 seconds.
a If any abnormality is detected by the check be-
fore starting, the screen changes to “Display of
warning after check before starting” or “Display
of ending of maintenance interval”.
a If no abnormality is detected by the check before
starting, the screen changes to “Display of
check of working mode and travel speed”.
a The monitors (6 pieces) displayed on the screen
Display of check of breaker mode are the items under the check before starting.
When the starting switch is turned ON, if the working
mode is set to the breaker mode [B], a message to
inform the operator of starting in the breaker mode
is displayed on the screen.
k If an attachment other than the breaker is
used while the working mode is set to the
breaker mode [B], the machine may move un-
expectedly or may not operate normally or
the hydraulic components may be damaged.
a After operation to check of the breaker mode is
finished, the screen changes to “Display of
check before starting”.
If No is selected: Working mode is set to
economy mode [E]
If Yes is selected: Working mode is set to
breaker mode [B]
PC400, 450-8R 7
Display of warning after check before starting Display of check of working mode and travel
If any abnormality is detected by the check before speed
starting, the warning monitor is displayed on the If the check before starting is finished normally, the
screen. screen to check the working mode and travel speed
a The following figure shows that the engine oil is displayed for 2 seconds.
level monitor(a) is warning of low of engine oil a After display of check of the working mode and
level. travel speed is finished, the screen changes to
“Display of ordinary screen”.
Display of ending of maintenance interval

When the check before starting is carried out, if a Display of ordinary screen
maintenance item is near or after the end of the set If the machine monitor starts normally, the ordinary
interval, the maintenance monitor is displayed for 30 screen is displayed.
seconds to urge the operator to maintenance. a Service meter (a) or a clock is displayed at the
a This screen is displayed only when the mainte- center upper section of the screen (The service
nance function is effective. The color of the meter or clock is selected with [F4]).
maintenance monitor (yellow or red) indicates a ECO gauge (b) is displayed at the right end of
the length of the time after the maintenance in- the screen (It is turned ON and OFF in the ser-
terval. vice mode).
a Set or change the maintenance function in the
service mode.
a After display of this screen is finished, the screen
changes to “Display of check of working mode
and travel speed”.
8 PC400, 450-8R
Display of end screen Selection of working mode

When the starting switch is turned OFF, the end Select a working mode according to the following
screen is displayed for 5 seconds. procedure.
a Another message may be displayed on the end 1. While the ordinary screen is displayed, press the
screen, depending on the message display func- working mode selector switch, and the working
tion of KOMTRAX. mode selection screen is displayed.
a The following figure is the working mode se-
lection screen displayed when "With attach-
ment" is set (If "With attachment" is not set in
the service mode, the attachment mode
[ATT] is not displayed).
Selection of auto-deceleration
While the ordinary screen is displayed, if the au-
to-deceleration switch is pressed, large auto-decel-
eration monitor (a) is displayed for 2 seconds and
the setting of the auto-deceleration is changed.
a Each time the auto-deceleration switch is 2. Operate the function switches or working mode
pressed, the auto-deceleration is turned ON and selector switch to select and confirm the working
OFF alternately. mode which you will use.
a If the auto-deceleration is turned ON, large mon- Function switches
itor(a) and auto-deceleration monitor (b) are dis- q [F3]: Move to lower working mode
played simultaneously. q [F4]: Move to upper working mode
a If the auto-deceleration is turned OFF, auto-de- q [F5]: Cancel selection and return to ordinary
celeration monitor (b) goes off. screen
q [F6]: Confirm selection and return to ordinary
screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function switch-
es and working mode selector switch for 5
seconds, the selection is confirmed and the
screen changes to the ordinary screen.
PC400, 450-8R 9
3. When the ordinary screen is displayed again, Selection of travel speed

large working mode monitor(a) is displayed for 2 While the ordinary screen is displayed, if the travel
seconds, and then the setting of the working speed shifting switch is pressed, large travel speed
mode is changed. monitor (a) is displayed for 2 seconds and the set-
a When large monitor (a) is displayed, the dis- ting of the travel speed is changed.
play of working mode monitor (b) is changed, a Each time the travel speed shifting switch is
too. pressed, the travel speed is changed to Lo, Mi,
Hi, and Lo again in order.
a When large monitor (a) is displayed, the display
of travel speed monitor (b) is changed, too.
<Precautions for selecting breaker mode [B]>

q If breaker mode [B] is selected, both of the
control of the hydraulic pump and the setting
of the hydraulic circuit are changed. Operation to stop alarm buzzer
q If an attachment other than the breaker is While the alarm buzzer is sounding, if the alarm
used, the machine may move unexpectedly buzzer cancel switch is pressed, the alarm buzzer
or may not operate normally or the hydraulic stops.
components may be damaged. a Even if the alarm buzzer cancel switch is
q After the breaker mode is selected, the pressed, the screen does not change.
screen to confirm the selection of the breaker
mode is displayed (The buzzer sounds inter-
mittently while this screen is displayed).
q If the setting is confirmed on this screen, the
screen changes to the ordinary screen.
If No is selected: Screen returns to screen to
select working mode.
If Yes is selected: Working mode is set to
breaker mode [B]
10 PC400, 450-8R
Operation of windshield wiper Operation of air conditioner/heater

While the ordinary screen is displayed, if the wiper While the ordinary screen is displayed, press the air
switch is pressed, large wiper monitor (a) is dis- conditioner switch or heater switch, and the air con-
played for 2 seconds and the windshield wiper starts ditioner adjustment screen or heater adjustment
or stops. screen is displayed.
a Each time the wiper switch is pressed, the wind- a While the air conditioner adjustment screen or
shield wiper setting is changed to INT, ON, OFF, heater adjustment screen is displayed, if you do
and INT again in order. not touch any switch for 5 seconds, the screen
a When large monitor (a) is displayed, the display changes to the ordinary screen.
of wiper monitor (b) is changed or turned OFF, a Air conditioner specification
too.
a If the windshield wiper is turned OFF, large mon-
itor (a) is not displayed.
a Heater specification
Operation of window washer

While the ordinary screen is displayed, if the window
washer switch is pressed, the washing liquid is
splashed only while the switch is held down.
a Even if the window washer switch is pressed, the
screen does not change.
PC400, 450-8R 11
Operation to display camera mode (if camera is Operation to display clock and service meter
installed) While the ordinary screen is displayed, press [F4],
When a camera is installed, if [F3] is pressed, the and section (a) changes to the service meter and
multi-display changes to the camera image (Set the clock alternately.
connection of the camera in the service mode). a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.
a Up to 3 cameras can be connected. If the cam-

era mode is selected, however, only the image of
camera 1 is always displayed.
a If a caution is generated in the camera mode, the

caution monitor is displayed at the left upper of
the screen (The low hydraulic oil temperature
caution is not displayed there, however).
a When an error that there is a user code occurs in
the camera mode, if you do not touch any control
lever for 10 seconds, the screen changes to the
ordinary screen and displays the error informa-
tion.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is
displayed on the right side. The image of
camera 3 is displayed only singly.
a If the images of 2 cameras are displayed simul-
taneously, images are displayed at intervals of 1
second on the right and left screen.
12 PC400, 450-8R
Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen is (Including KOMTRAX messages for user)
displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.
a To reset the time left after finishing maintenance, a There are following items in the user menu.
more operations are necessary. Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
a The breaker/attachment setting menu is dis-
played only when "With attachment" is set in the
service mode.
PC400, 450-8R 13
[KOMTRAX message] Display of energy-saving guidance

q There are 2 types of KOMTRAX message; 1 is When the machine is set in a certain operating con-
for the user and the other is for the service. dition, the energy-saving guidance screen is dis-
q For user: played automatically to urge the operator to the
A message transmitted from the KOMTRAX energy-saving operation.
base station for the user. If it is received, the a The energy-saving guidance is displayed when
message monitor is displayed on the ordinary the following condition is satisfied while the dis-
screen. To see the contents of the message, play setting is set effective in the service mode.
operate "User Message" in the above user a Condition for display:
menu. Engine is running + All levers have been in
q For service: neutral for 5 minutes + Caution (Note) or user
A message transmitted from the KOMTRAX code is not generated (Note)
base station for the service. Even if it is received, Note: Excluding hydraulic oil low temperature
nothing is displayed on the ordinary screen. To caution
see the contents of the message, operate a If any lever or pedal is operated, or [F5] is
"KOMTRAX message" display in the service pressed, the screen returns to the ordinary
menu. screen.
Display of caution monitor

If an abnormality which displays a caution monitor
occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution moni-
tor flashes at the left upper of the screen when
the caution is generated.
14 PC400, 450-8R
Display of automatic judgment of breaker Display of user code and failure code
If the operator performs breaker work in an improper If an abnormality which displays a user code and a
working mode, the breaker automatic judgment failure code occurs on the ordinary screen or cam-
screen is displayed to urge the operator to select a era mode screen, all the information of the abnor-
proper working mode. mality is displayed.
a The breaker automatic judgment is displayed (a): User code (3 digits)
when the following condition is satisfied while (b): Failure code (5 or 6 digits)
the display setting is set effective in the service (c): Telephone mark
mode. (d): Telephone No.
a Condition for display: a This screen is displayed only when an abnormal-
When the pump controller measures the rear ity (failure code) for which a user code is set oc-
pump pressure for a certain time, the obtained curs.
value is similar to the pulsation wave form of a The telephone mark and telephone No. are dis-
breaker operation which is held in the controller played only when the telephone No. is registered
in advance. in the service mode.
a The breaker automatic judgment function is set a If multiple abnormalities occur simultaneously,
to Not used (Not displayed) when delivered. all the codes are displayed repeatedly in order.
a If this screen is displayed, check the setting of a Since the information of the displayed failure
the working mode. If the breaker is being used, code is recorded in the abnormality record in the
select the breaker mode [B]. service mode, check the details in the service
a To return to the ordinary screen, press [F5]. mode.
a When the caution monitor is also displayed, the

telephone mark is not displayed.
PC400, 450-8R 15
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency) posi-
E02 Pump control system error tion, 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
E10 Engine controller drive system Have inspection carried out immediately.
circuit error
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried out
E11
Output reduced to protect engine immediately.
Operate machine to a safe posture and have inspection carried out
E14 Abnormality in throttle system
immediately.
Engine sensor (coolant tempera-
E15 ture, fuel pressure, oil pressure) Operations are possible, but have inspection carried out immediately.
system error
Operate machine to a safe posture and have inspection carried out
E0E Network error
immediately.
16 PC400, 450-8R
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are op- as follows. At this time, only the service meter sec-
erated as follows, all the LCD (Liquid Crystal tion displays.
Display) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the LCD,
a When finishing the operation of the switches, re- hold down the switches until the LCD displays
lease [F2] first. normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continuously,
part is indicated in black. blue points (points which do not go off) may be
a The LCD panel sometimes has black points seen on this screen. This phenomenon does not
(points which are not lighted) and bright points indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright points
and black points does not exceed 10, those
points are not a failure or a defect.
a To return to the former screen, press the function
switch.
PC400, 450-8R 17
Function of changing attachment/maintenance 3. After the New password input screen is

password displayed, input a new password with the
When changing the attachment/maintenance pass- numeral input switches and confirm it with the
word used for the attachment setting function and function switch.
maintenance setting function, follow these proce- a Set a new password of 4 – 6 digits (If it has
dures. only 3 or less digits or has 7 or more digits, it
1. While the ordinary screen is displayed, perform is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordinary
switches. screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4]+[5]o[5]o[5]
a This operation of the switches is not accept-
ed until 10 minutes pass after the starting
switch is turned on.
4. After the New password input screen is

displayed again, input a new password again
with the numeral input switches and confirm it
with the function switch.
q [F5]: Reset input numeral/Return to ordinary
2. After the Attachment/Maintenance PASSWORD screen
screen is displayed, input the current password q [F6]: Confirm input numeral
with the numeral input switches and confirm it a If a password different from the password in-
with the function switch. put before is input, the message to input
q [F5]: Reset input numeral/Return to ordinary again is displayed.
screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the mes-
sage to input the password again is dis-
played.
18 PC400, 450-8R
5. If the screen to notify completion of setting is

displayed and then the ordinary screen is
displayed, the password is changed success-
fully.
PC400, 450-8R 19
t Service mode a The items which can be selected in the ser-

To change the operator mode to the service mode, vice menu are as follows (including some
perform the following operation. items which need special operations).
This operation is always required when you use the 01 Monitoring
service mode. Mechanical Systems
02 Abnormality Electrical Systems
1. Check of display of screen and operation of Record Air-conditioning System/Heater
switches System
03 Maintenance Record
While the ordinary screen is displayed, perform
04 Maintenance Mode Change
the following operation with the numeral input 05 Phone Number Entry
switches. Key-on Mode
q Operation of switches (While pressing [4], Unit
perform the operation in order): With/Without Attachment
[4] + [1] o [2] o [3] 06 Default
Attachment/Maintenance Pass-
a This operation of the switches is accepted word
Camera
only while the ordinary screen is displayed.
ECO Display
Breaker Detect
Pump Absorption Torque
07 Adjustment Low Speed
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
10 Fuel Consumption
Terminal Status
11 KOMTRAX GPS & Communication Status
Settings MODEM S/N (TH300)
MODEM IP Address (TH200)
2. Selection of service menu

When the Service menu screen is displayed, the
service mode is selected. Select a service menu
you use with the function switches or numeral
input switches.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numer-
al input switches to select the menu of that
code and confirm it with [F6].
20 PC400, 450-8R
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
1. Selecting menu
Select “Monitoring” on the service menu screen.
3. Deciding monitoring items

After selecting monitoring items, execute moni-
toring with the function switch or numeral input
switch.
a Execution with function switch: Double-click
or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for example,
2. Selecting monitoring items select them and confirm with [F6]. If [F6] is
After the “Monitoring selection menu screen” is pressed once more at this time, monitoring is
displayed, select items to be monitored with the executed.
function switches or numeral input switches. a If monitoring items are selected up to the limit
q [F1]: Move to next page (screen) number, monitoring is executed automatical-
q [F2]: Move to previous page (screen) ly.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Reset input numeral/Return to service
menu screen
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is se-
lected directly. Confirm that item with [F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is confirmed.
a Up to 6 monitoring items can be selected at a
time. You may not able to set up to 6 items,
however, depending on the display form of
those items.
PC400, 450-8R 21
4. Executing monitoring 6. Changing machine setting mode

After the “Executing monitoring screen” is To change the setting of the working mode,
displayed, perform the necessary operation of travel speed, or auto-deceleration during moni-
the machine and check the monitoring informa- toring, operate the corresponding switch under
tion. the current condition, and the mode setting
a Monitoring information is indicated by value, screen is displayed.
ON/OFF, or special display. While this screen is displayed, if the corre-
a The unit of display can be set to SI unit, met- sponding switch is operated further, the corre-
ric unit, or inch unit with the Initialization func- sponding mode is changed.
tion in the service mode. a After finishing changing the setting, press
[F6] to return to the monitoring information
screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitor-
ing is finished.
5. Holding monitoring information

The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold information (displayed data)
q [F5]: Return to monitoring selection menu
screen a If the working mode is changed to breaker
mode [B], the screen to confirm the change of
the setting is displayed as in changing the
working mode on the ordinary screen.
22 PC400, 450-8R
Monitoring items table

Code Unit (Initial setting: ISO) Component
Monitoring item (Display on screen) Remarks
No. ISO meter inch in charge
00200 Controller Model Select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure Mpa kg/cm2 psi PUMP
01101 R Pump Pressure Mpa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure Mpa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure Mpa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure Mpa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indica-
36500 Boost Pressure kPa kg/cm2 psi ENG tion (including atmo-
spheric pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command Mpa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
Swing ON•OFF PUMP
Travel ON•OFF PUMP
Pressure Boom Lower ON•OFF PUMP
01900
Switch 1 Boom Raise ON•OFF PUMP
Arm Curl ON•OFF PUMP
Arm Dump ON•OFF PUMP
Bucket Curl ON•OFF PUMP
Pressure Bucket Dump ON•OFF PUMP
01901
Switch 2 Service ON•OFF PUMP
Travel Steering ON•OFF PUMP
Travel Junction ON•OFF PUMP
Swing Brake ON•OFF PUMP
Solenoid Valve
02300 Merge-divider ON•OFF PUMP
1
2-Stage Relief ON•OFF PUMP
Travel Speed ON•OFF PUMP
Solenoid Valve
02301 Service Return ON•OFF PUMP
2
PC400, 450-8R 23
Code Unit (Initial setting: ISO) Component

Monitoring item (Display on screen) Remarks
No. ISO meter inch in charge
Lever Sw. ON•OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON•OFF PUMP
Swing Brake Sw. ON•OFF PUMP
Model Select 1 ON•OFF PUMP
02201 Switch Input 2
Overload Alarm ON•OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON•OFF PUMP
Controller Out-
03700 Batt. Relay Dr. ON•OFF MON
put 1
Key Switch ON•OFF MON
Start ON•OFF MON
04500 Monitor Input 1 Preheat ON•OFF MON
Light ON•OFF MON
Rad. Level ON•OFF MON
Air cleaner ON•OFF MON
04501 Monitor Input 2 Eng. Oil Level ON•OFF MON
Battery Charge ON•OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON•OFF MON
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No — ENG
20206 Monitor Prog. Version — MON
20212 Pump Con. Prog. Version — PUMP
a Entry order of items in table

The items are entered in the order of display on the monitoring selection menu screen.
a Unit
The display unit can be set to ISO, meter, or inch freely (Set it with Unit selecting in Initialization of the
service menu).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of monitoring information.
ENG: The engine controller is in charge of detection of monitoring information.
PUMP: The pump controller is in charge of detection of monitoring information.
24 PC400, 450-8R
Abnormality Record (Mechanical Systems) 3. Information displayed on “abnormality record”

The machine monitor classifies and records the ab- screen
normalities which occurred in the past or which are On the “Mechanical Systems” screen, the
occurring at present into the mechanical systems, following information is displayed.
electrical systems, and air-conditioning system or (a): Occurrence order of abnormalities from
heater system. latest one/Total number of records
To check the mechanical system abnormality re- (b): Failure code
cord, perform the following procedures. (c): Contents of trouble
(d): Number of occurrence time (Displayable
1. Selecting menu range: 0 – 65,535 times)
Select “Abnormality Record” on the “Service (e): Service meter reading at first occurrence
Menu” screen. (f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
q [F5]: Return to abnormality record screen
a If no abnormality record is recorded, "No ab-
normality record" is displayed.
a If the number of occurrence time is 1 (first oc-
currence), the service meter reading at the
first occurrence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
of it has not been confirmed.
a For all the failure codes that the machine
2. Selecting sub menu
monitor can record, see the failure codes ta-
After the “Abnormality Record” screen is
ble in “Abnormality Record (Electrical
displayed, select “Mechanical Systems” with
Systems)”.
the function switches or numeral input switches.
q [F5]: Return to service menu screen
al input switches to select the record of that
a The following figure shows the display of the
air conditioner specification. The heater
specification and heaterless specification are
different from each other in the display of "03
Air-conditioning System", which may not be
displayed in the heaterless specification.
PC400, 450-8R 25
4. Resetting abnormality record

The contents of the mechanical system abnor-
mality record cannot be reset.
Abnormality Record (Electrical Systems)

The machine monitor classifies and records the ab-
normalities which occurred in the past or which are
occurring at present into the mechanical systems,
electrical systems, and air-conditioning system.
To check the electrical system abnormality record,
perform the following procedures.
1. Selecting menu
Select “Abnormality Record” on the “Service 3. Information displayed on “abnormality record”
Menu” Screen. screen
On the “Electrical Systems” screen, the
following information is displayed.
(a): Occurrence order of abnormalities from
latest one/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time (Displayable
range: 0 – 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if dis-
played)
q [F2]: Move to previous page (screen) (if dis-
played)
2. Selecting sub menu q [F3]: Move to lower item
After the “Abnormality Record” screen is q [F4]: Move to upper item
displayed, select “Electrical Systems” by the q [F5]: Return to “abnormality record” screen
function switches or numeral input switches. a If no abnormality record is recorded, "No ab-
q [F3]: Move to lower item normality record" is displayed.
q [F4]: Move to upper item a If the number of occurrence time is 1 (first oc-
q [F5]: Return to service menu screen currence), the service meter reading at the
q [F6]: Confirm selection first occurrence and that at the last occur-
a You may enter a 2-digit code with the numer- rence are the same.
al input switches to select the item of that a If [E] is displayed on the left of a failure code,
code and confirm it with [F6]. the abnormality is still occurring or resetting
a The following figure shows the display of the of it has not been confirmed.
machine with air conditioner. a For all the failure codes that the machine
The heater specification and heaterless monitor can record, see the failure codes ta-
specification are different from each other in ble.
the display of "03 Air-conditioning System",
which may not be displayed in the heaterless
specification.
26 PC400, 450-8R
4. Resetting abnormality record 3) After the “Electrical Sys. Error Reset” screen
1) While the “Electrical Systems” screen is is displayed, operate the function switches.
displayed, perform the following operation q [F5]: Return to “Electrical systems”
with the numeral input switches. screen (Reset mode)
q Operation of switches (While pressing [4], q [F6]: Execute reset
perform the operation in order): a The following figure shows the screen
[4] + [1] o [2] o [3] displayed when the items are reset one
by one (which is a little different from the
screen displayed when all the items are
reset together).
2) Check that the screen is set in the reset

mode, and then reset the items one by one or
together with the function switches.
a If the screen is set in the reset mode, 4) If the screen to notify completion of reset is
[CLEAR] graphic mark is indicated at displayed and then the “Electrical Systems”
[F2]. (reset mode) screen is displayed, the reset of
q [F2]: Reset all items the abnormality record is completed.
q [F3]: Move to lower item a After a while, the screen returns to the
q [F4]: Move to upper item “Electrical Systems” screen.
q [F5]: Return to abnormality record screen
q [F6]: Reset selected item
a To reset items one by one: Select the item
to be reset with [F3] or [F4] and press
[F6].
a To reset all items together: Press [F2],
and all the items are reset, regardless of
selection of the items.
a If [E] is displayed on the left of a failure
code, the resetting operation is accepted
but the information is not reset.
PC400, 450-8R 27
Failure codes table

Device in
User code Failure code Trouble (Displayed on screen) Category of record
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
E02 B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle Sensor Low Error ENG Electrical system
E15 CA135 Eng. Oil Press Sensor High Error ENG Electrical system
E15 CA141 Eng. Oil Press Sensor Low Error ENG Electrical system
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
— CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E15 CA263 Fuel Temp Sensor Hight Error ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error ENG Electrical system
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E10 CA273 PCV2 Short Error ENG Electrical system
E10 CA274 PCV2 Open Error ENG Electrical system
E11 CA322 Inj #1 (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
E11 CA449 Rail Press Very High Error ENG Electrical system
28 PC400, 450-8R
Device in
charge
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
E11 CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Ne Speed Sensor Error ENG Electrical system
E15 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E15 CA778 Bkup Speed Sensor Error ENG Electrical system
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
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 power supply output 1 abnormality PUMP Electrical system
E0E DA2RMC CAN discon (Pump condetected) PUMP Electrical system
— DA2SKQ Model Selection Abnormality PUMP Electrical system
E0E DAFRMC CAN discon (Monitor condetected) PUMP Electrical system
— DHPAMA F Pump P. Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump P. Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Sen. Abnormality PUMP Electrical system
— DW43KA Travel Speed Sol. Disc. PUMP Electrical system
— DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C PUMP Electrical system
— DW91KA Travel Junction Sol. Disc. PUMP Electrical system
— DW91KB Travel Junction Sol. S/C PUMP Electrical system
— DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
— DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
— DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
— DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
— DXE0KB LS-EPC Sol. S/C PUMP Electrical system
— DXE4KA Service Current EPC Disc. PUMP Electrical system
— DXE4KB Service Current EPC S/C PUMP Electrical system
— DY20KA Wiper Working Abnormality PUMP Electrical system
— DY20MA Wiper Parking Abnormality PUMP Electrical system
— DY2CKB Washer Drive Short PUMP Electrical system
PC400, 450-8R 29
Device in
charge
— DY2DKB Wiper Drive (For) Short PUMP Electrical system
— DY2EKB Wiper Drive (Rev) Short PUMP Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine mon-
itor.
a Entry order of items in table
The items are entered in the order of their failure codes (incremental order).
a User code
Attached: If the failure code is detected, the user code, failure code, and telephone No. (if registered)
are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
30 PC400, 450-8R
Abnormality Record (Air-conditioning Sys- 3. Information displayed on “abnormality record”

tem/Heater System) screen
The machine monitor classifies and records the ab- On the “Air-conditioning System” or “Heater
normalities which occurred in the past or which are System” screen, the following information is
occurring at present into the mechanical systems, displayed.
electrical systems, and air-conditioning abnormali- (a): System/Component name
ties or heater abnormalities. (b): Number of occurrence time
To check the air-conditioning abnormality record or (c): Condition (Normal or abnormal)
heater abnormality record, perform the following q [F2]: Reset abnormality record
procedures. q [F5]: Return to abnormality record screen
a All the following figures show the air conditioner a If [E] is displayed on the left of a condition,
specification. the abnormality is still occurring or resetting
of it has not been confirmed.
1. Selecting menu a If CAN disconnection is displayed in Commu-
Select “Abnormality Record” on the “Service nication condition, communication cannot be
Menu” screen. carried out normally. Accordingly, the condi-
tions of other items are turned OFF.

After the “Abnormality Record” screen is 4. Resetting abnormality record
displayed, select “Air-conditioning System” or While the “abnormality record” screen is
“Heater System” with the function switches or displayed, press [F2], and the number of occur-
numeral input switches. rence time of abnormality is reset. If it is
q [F3]: Move to lower item confirmed at this time that the abnormality has
q [F4]: Move to upper item been reset, the display changes to Normal.
q [F6]: Confirm selection a Heater specification
a You may enter a 2-digit code with the numer- In the heater specification, the display of
al input switches to select the record of that “Air-conditioning” is replaced with “Heater”
code and confirm it with [F6]. and the items which are not related to the
heater are not displayed.
a Heaterless specification
In the heaterless specification, the abnor-
mality record menu and screen are not
displayed.
PC400, 450-8R 31
Maintenance Record a The following items can be selected in the

The machine monitor records the maintenance in- maintenance record.
formation of the filters, oils, etc., which the operator 01 Engine oil change
can display and check by the following operations. 02 Engine oil filter change
When maintenance is carried out, if the data are re- 03 Fuel main filter change
set in the operator mode, the number of the times of 41 Fuel pre-filter change
maintenance is recorded in this section. 04 Hydraulic oil filter change
05 Hydraulic tank breather change
1. Selecting menu 06 Corrosion resistor change
Select “Maintenance Record” on the “Service 07 Damper case service
Menu” screen. 08 Final drive case oil change
09 Machinery case oil change
10 Hydraulic oil change
3. Items displayed on maintenance record screen

The following items are displayed.
(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement
2. Selecting maintenance record item

After the “Maintenance Record” screen is
displayed, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Move to next page (screen)
q [F2]: Move to previous page (screen)
al input switches to select the item of that
code.
32 PC400, 450-8R
Maintenance Mode Change a The following items can be selected on the

The operating condition for maintenance function in Change of maintenance mode screen.
the operation mode can be set and changed with 00 Maintenance mode on/off
this menu. 01 Engine oil change int.
q Set function effective or ineffective 02 Engine oil filter change int.
q Change set replacement interval (by items) 03 Fuel main filter change int.
q Initialize all set replacement intervals 41 Fuel pre filter change int.
04 Hyd oil filter change int.
1. Selecting menu 05 Hyd tank breather change int.
Select of “Maintenance Mode Change” on the 06 Corrosion resistor change int.
“Service Menu” screen. 07 Damper case service int.
08 Final drive case oil change int.
09 Machinery case change int.
10 Hydraulic oil change int.
99 Use Default Value
3. Contents of setting of Maintenance mode on/off

After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set ON or OFF with the
function switches.
q ON: Functions of all maintenance items are
set effective in operator mode
q OFF: Functions of all maintenance items are
set ineffective in operator mode
2. Selecting sub menu q [F4]: Move to upper item
After the “Maintenance Mode Change” screen q [F5]: Cancel selection and return to Mainte-
is displayed, select an item to change the setting nance mode change screen
with the function switches or numeral input q [F6]: Confirm selection and return to Mainte-
switches. nance mode change screen
q [F1]: Move to next page (screen) a Even if ON/OFF of each item has been set, if
q [F2]: Move to previous page (screen) the above setting is changed, it is applied.
al input switches to select the item of that
PC400, 450-8R 33
4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting “99 Use Default Value”, if the
screen is displayed, set the item with the function screen is displayed, set with the function
switches. switches.
q Initial value: Maintenance interval set in ma-

chine monitor (Recommended by manufac-
turer and not changeable).
q Set value: Maintenance interval which can be
set freely. Maintenance functions in operator
mode operate on basis of this set time (which
is increased or decreased by 50 hours).
q ON: Maintenance function of this item is set
effective in operator mode.
q OFF: Maintenance function of this item is set
ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or OFF
(Lower).
q If this operation is executed, the set values of
q [F4]: Select Increase set value (Upper) or ON
all the maintenance items are initialized.
(Lower).
q [F5]: Return to Maintenance mode change
q [F5]: Cancel setting before confirmation and
screen
return to Maintenance mode change screen.
q [F6]: Execute initialization
q [F6]: Confirm setting of upper or lower line.
a A while after [F6] is pressed, the initialization
a After the setting of the upper and lower lines
completion screen is displayed. Then, if the
is confirmed with [F6] and the screen chang-
“Maintenance Mode Change” screen is dis-
es to the Maintenance mode change screen
played, initialization is completed.
with [F5], the setting is effective.
a If the set value of an item set to “ON” is
changed after 1 or more operating hours
since the start of setting, the change is recog-
nized as a resetting operation.
34 PC400, 450-8R
Phone Number Entry a If [F6] is pressed without inputting a digit,

The telephone No. displayed when the user there is not information of telephone No. Ac-
code/failure code is displayed in the operator mode cordingly, no telephone No. is displayed in
can be input and changed according to the following the operator mode.
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select “Phone Number Entry” on the “Service
Menu” screen.
2. Registering and changing telephone No.

After the “Phone Number Entry” screen is
displayed, register or change the telephone No.
q [F2]: Reset all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Reset input digit/Return to service menu
q [F6]: Confirm input
a Up to 14 digits can be input from the left. In-

put nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and overwrite
it with the correct digit.
PC400, 450-8R 35
Default (Key-on Mode) q Mode at Previous Key-off: Final mode in pre-

Check or change various settings related to the ma- vious operation is displayed when key is ON
chine monitor and machine by "Default". q [F3]: Move to lower item
The function of working mode with key ON is used q [F4]: Move to upper item
to set the working mode displayed on the machine q [F5]: Cancel selection and return to “Default”
monitor when the starting switch is turned ON. screen
q [F6]: Confirm selection and return to
1. Selecting menu “Default” screen
Select “Default” on the “Service Menu” screen. a When the machine is delivered, Mode at pre-
vious key-OFF is set.
a If "With attachment" is not set, the attach-
ment mode cannot be selected.
a While Attachment mode [ATT] is selected, if
"Without attachment" is set, Power mode [P]
is displayed when the key is turned ON.
a If the engine is stopped while breaker mode
[B] is selected in the operator mode, Breaker
mode [B] is always displayed, regardless of
the above setting.

After the “Default” screen is displayed, select
“Key-on Mode” with the function switches or
numeral input switches.
a Select this item similarly to an item on the
“Service Menu” screen.
3. Selecting mode
After the “Key-on Mode” screen is displayed,
select the mode to be set with the function
switches.
q Power Mode: [P] is displayed when key is ON
q Economy Mode: [E] is displayed when key is
ON
q Lifting Mode: [L] is displayed when key is ON
q Breaker Mode: [B] is displayed when key is
ON
q Attachment Mode: [ATT] is displayed when
key is ON
36 PC400, 450-8R
Default (Unit) a When the machine is delivered, the SI unit

Check or change various settings related to the ma- system is set.
chine monitor and machine by "Default".
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select “Default” on the “Service Menu” screen.

“Unit” with the function switches or numeral
input switches.
3. Selecting unit
After the “Unit” screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower unit
q [F4]: Move to upper unit
q [F5]: Cancel selection and return to “Default”
screen
q [F6]: Confirm selection and return to
“Default” screen
PC400, 450-8R 37
Default (With/Without Attachment) a When an attachment is installed, if this set-

Check or change various settings related to the mating is not carried out normally, the attach-
chine monitor and machine by "Default". ment cannot be set in the operator mode. As
The "With/Without attachment" function is used to a result, the attachment may not work nor-
set an installed or a remove attachment. mally or the hydraulic components may have
trouble.
1. Selecting menu
Select "Default" on the “Service Menu” screen.

After the "Default" screen is displayed, select
“With/Without Attachment” with the function
switches or numeral input switches.
3. Selecting With/Without
After the “With/Without Attachment” screen is
displayed, select the setting with the function
switches.
q Without Attachment: When attachment is not
installed
q With Attachment: When attachment is in-
stalled
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
38 PC400, 450-8R
Default (Attachment/Maintenance Password) 3. Selecting Disable/Enable

Check or change various settings related to the ma- After the Attachment/Maintenance Password
chine monitor and machine by "Default". screen is displayed, select the setting with the
The function of setting attachment/maintenance function switches.
password is used to set the display of the password q Disable: Password screen is not displayed
screen when the functions related to the attachment q Enable: Password screen is displayed
and maintenance are used in the operator mode. q [F3]: Move to lower item
1. Selecting menu q [F5]: Cancel selection and return to "Default"
Select “Default” on the “Service Menu” screen. screen
q [F6]: Confirm selection and return to "De-
fault" screen

“Attachment/Maintenance Password” with the 4. Displaying attachment/maintenance password
function switches or numeral input switches. screen
a Select this item similarly to an item on the When the following operation is performed, the
“Service Menu” screen. password screen is displayed in the operator
mode.
q Maintenance mode: The Maintenance table
screen is changed to the Maintenance inter-
val reset screen.
q User mode: On the User menu screen, the
Breaker/Attachment setting menu is selected
and the screen is changed to the Attachment
setting menu screen.
5. Changing attachment/maintenance password

The password can be changed by operating the
switches specially in the operator mode.
a See Attachment/Maintenance password
changing function in the operator mode.
a Default password: [000000]
a If the password setting is changed from En-
able to Disable, the password is reset to the
default. When Enable is set again, be sure to
set a new password.
a The attachment/maintenance password is
different from the engine start lock password.
PC400, 450-8R 39
Default (Camera) 3. Selecting camera setting

Check or change various settings related to the ma- After the “Camera” setting screen is displayed,
chine monitor and machine by "Default". select the setting with the function switches.
The camera setting function is used to set installa- q OFF: Camera is not used
tion and removal of a camera. q Original Image: Image of connected camera
is displayed in original position (as in mirror,
1. Selecting menu used as back monitor)
Select "Default" on the "Service Menu" screen. q Reverse Image: Image of connected camera
is displayed in reverse position (as seen di-
rectly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
return to “Default” screen
q [F6]: Confirm selection in each line
a After “Camera” screen is displayed, camera
1 can be always set. When 2 or more cam-
eras are connected, if camera 1 is set, the
screen changes to setting of camera 2 auto-
matically.
a After confirming the setting of each line with
[F6], return to the "Default" screen with [F5],
and the setting is effective.
a If a camera is connected but not set normally
with this function, the graphic mark of camera
“Camera” with the function switches or numeral
is not displayed at [F3] in the operator mode.
input switches.
Accordingly, the image of the camera cannot
be used.
“Service Menu” Screen.
a If 2 or more cameras are connected, be sure
to set the use of them from camera 1 in order.
a The function of displaying 2 images simulta-
neously is effective when use of camera 1
and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizontally.
40 PC400, 450-8R
Default (ECO Display) a If ECO display is turned ON, ECO is dis-

Check or change various settings related to the ma- played when the screen changes to the ordi-
chine monitor and machine by "Default". nary screen. Even if the energy saving
The ECO display setting function is used to set the guidance is turned ON, however, it is not dis-
display of the ECO gauge and energy saving guid- played if the condition for display is not satis-
ance. fied on the ordinary screen.
1. Selecting menu
Select "Default" on the "Service Menu" screen.
a Display of ECO gauge (a)

“ECO Display” with the function switches or
a Display of energy saving guidance
3. Selecting display setting

After the “ECO Display” screen is displayed,
select the setting with the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
return to "Default" screen
q [F6]: Confirm selection in each line
a After confirming the setting of the upper and
lower lines with [F6], return to the "Default"
screen with [F5], and the setting is effective.
PC400, 450-8R 41
Default (Breaker Detect) 3. Selecting display setting

Check or change various settings related to the ma- After the "Breaker Detect" screen is displayed,
chine monitor and machine by "Default". select the setting with the function switches.
The function of setting breaker automatic judgment q [F3]: Move to lower item
is used to set the display to give warning when the q [F4]: Move to upper item
breaker is used in an improper working mode. q [F5]: Cancel selection and return to Default
screen
1. Selecting menu q [F6]: Confirm selection and return to Default
Select "Default" on the "Service Menu" screen. screen
a When the machine is delivered, Disable is
set.

After the “Default” screen is displayed, select a Display of "Breaker Detect"
"Breaker Detect" with the function switches or
“Service menu” screen.
42 PC400, 450-8R
Adjustment (Pump Absorption Torque) 3. Selecting absorption torque

The operator can adjust various items related to the After the "Pump Absorption Torque" screen is
machine with the machine monitor. displayed, select a set value on the right side
The pump absorption torque function is used to fine- with the function switches.
ly adjust the absorption torque on the front side of q Set value: For actual torque adjustment val-
the hydraulic pump. ue, see table
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” q [F4]: Decrease set value
screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen
a The 3 digits on the left side do not vary since
they are the code of this function.

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque” with the func-
a Relationship between set value and torque
tion switches or numeral input switches.
adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +78.4 Nm {+8 kgm}
001 +58.8 Nm {+6 kgm}
002 +39.2 Nm {+4 kgm}
003 +19.6 Nm {+2 kgm}
021 004 0 Nm {0 kgm}
005 -19.6 Nm {-2 kgm}
006 -39.2 Nm {-4 kgm}
007 -58.8 Nm {-6 kgm}
008 -78.4 Nm {-8 kgm}
PC400, 450-8R 43
Adjustment (Low speed) 3. Selecting travel Low speed

The operator can adjust various items related to the After the "Low Speed" setting screen is
machine with the machine monitor. displayed, select a set value on the right side
The travel Low speed setting function is used to with the function switches.
finely adjust the travel Low speed. q Set value: For actual travel Low speed value,
see table
ment menu screen

select “Low speed” with the function switches
or numeral input switches. a Relationship between set value and travel
a Select this item similarly to an item on the Low speed value
“Service Menu” screen. Set
Code Travel Low speed value
value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
44 PC400, 450-8R
Adjustment (Attachment Flow Adjustment) 3. Selecting distribution of oil flow

The operator can adjust various items related to the After the screen of "Attachment Flow Adjust-
machine with the machine monitor. ment" is displayed, select a set value on the right
The function of "Attachment Flow Adjustment" is side with the function switches.
used to finely adjust the oil flow to the attachment in q Set value: For actual distribution of flow, see
compound operation. table
ment menu screen

select “Attachment Flow Adjustment” with the
function switches or numeral input switches. a Relationship between set value and distribu-
a Select this item similarly to an item on the tion of flow to attachment
“Service Menu” screen. Set Distribution of flow to attach-
Code
value ment
000 50 %
001 70 %
044
002 100 %
003 40 %
PC400, 450-8R 45
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" opera-
tion with the machine monitor.
"Cylinder Cut-Out" operation means to run the en-
gine with 1 or more fuel injectors disabled electrical-
ly 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 abnor-
mal).
1. Selecting menu
Select “Cylinder Cut-Out” on the “Service
Menu” screen.
3. Resetting Cut-Out cylinder

When changing a cylinder to be Cut-Out or when
Cylinder Cut-Out operation is finished, select a
Cut-Out cylinder to be reset with the function
switches.
a This operation may be performed while the
engine is running.
a When [F6] is pressed, if background(a) of the
selected cylinder No. becomes blue, the cyl-
inder is reset.
a If the machine monitor resets a Cut-Out cyl-
inder but the engine controller cannot reset
that Cut-Out cylinder, the background (a) of
2. Selecting cylinder to be disabled the cylinder No. becomes red.
After the "Cylinder Cut-Out" screen is displayed, a The Cut-Out operation is not automatically
select a cylinder to be Cut-Out with the function reset after the screen returns to the operator
switches. mode. Accordingly, be sure to perform the re-
q [F1]: Move selection mark (R) to left setting operation after the cylinder cut-out
q [F2]: Move selection mark (R) to right operation is finished.
q [F3]: Reset holding
q [F4]: Hold 4. Function of holding displayed information
q [F5]: Return to service menu screen If [F4] is pressed during the cylinder Cut-Out
q [F6]: Confirm selection operation, the displayed information is newly
a This operation may be performed while the held(c) (The real-time information is kept
engine is running. displayed on the left side).
a When [F6] is pressed, if background (a) of While the information is held, if [F3] is pressed,
the selected cylinder No. becomes white, the the holding function is reset.
cylinder is Cut-Out. a The holding function is effective, regardless
a IIf the machine monitor Cut-Out a cylinder of setting of the reduced cylinder mode oper-
but the engine controller cannot Cut-Out that ation.
cylinder, the background (a) of the cylinder
No. becomes yellow.
a One or more cylinders can be Cut-Out.
a In the cylinder Cut-Out operation, the au-
to-deceleration function can be selected. If
the auto-deceleration is turned ON, auto-de-
celeration monitor (b) is displayed.
46 PC400, 450-8R
[Reference] No Injection
q If a normally operating cylinder is Cut-Out, the If the engine is operated after long storage of the
following phenomena occur. machine, it may be worn or damaged because of in-
1) Lowering of engine speed sufficient lubrication with oil. To prevent this, the
2) Increase of final injection rate command function to lubricate the engine before starting it by
(quantity) cranking it without injecting fuel is installed.
q If the engine is running near the high idle, how- Set the no-injection cranking while the engine is
ever, the engine speed may not lower for the stopped.
reason of engine control.
q In this case, lower the engine speed with the fuel 1. Selecting menu
control dial and judge by increase of the injection Select “No Injection” on the “Service Menu”
rate command. screen.
2. Displaying check screen

If the "No injection" screen is displayed, the
machine monitor asks the operator if no injection
cranking should be performed. Answer with the
function switch.
q [F5]: Do not perform (Return to Service menu
screen)
q [F6]: Perform
a While the screen is changing to the following
screen, the screen of "Communication be-
tween controllers is being checked" is dis-
played.
PC400, 450-8R 47
3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (Fuel injection in no cylin- If the operator tries to perform the no injection
ders) becomes effective, that is displayed on the cranking while the engine is running, the
screen. Under this condition, crank the engine message that the engine is running is displayed
with the starting motor. and the no injection cranking is not set effective.
a While the screen is changing to the following a This function can be selected even while the
screen, the screen of "Setting is being pre- engine is running. If the no injection cranking
pared" is displayed. is performed, however, the message of "En-
a Limit the cranking time to 20 seconds to pro- gine is running" is displayed on the screen.
tect the starting motor.
4. Finishing no injection cranking

After completing the no injection cranking opera-
tion, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the “Service Menu” screen automatically.
48 PC400, 450-8R
Fuel Consumption 3. Display and function during measurement

This function calculates the hourly fuel consumption Clock mark (a) flashes during measurement.
from the actual fuel consumption in a measuring pe- a While the fuel consumption is being mea-
riod and indicates it. sured, the operator can work with the opera-
1. Selecting menu tor mode and other functions. Measurement
Select “Fuel Consumption” on the “Service is not finished until this screen is displayed
Menu” screen. again and [F1] is pressed (Even if the starting
switch is turned OFF, this function is kept ef-
fective, although fuel consumption is mea-
sured only while the engine is running).
2. Starting measurement
After the screen of “Fuel Consumption” is
displayed, start measurement with the function
switches. 4. Finishing measurement
q [F1]: Start Press [F1], and measurement is finished and the
q [F2]: Clear data are displayed on the finishing date and time
q [F5]: Return to Service menu screen side.
a When the screen of Fuel consumption is dis-
played, if a data is indicated, it is the data of 5. Displaying fuel consumption
the previous measurement. This data is not If the measurement is finished, the hourly fuel
an obstacle to new measurement and can be consumption calculated from the fuel consump-
reset by pressing [F2]. tion calculated by the engine controller and the
a If [F1] is pressed, the data is displayed on the elapsed time are displayed.
starting date and time side and measurement
starts.
a The display unit of the fuel changes accord-

ing to the unit set with the default (unit set-
ting) function.
SI and meter: l/h
inch: gal/h
PC400, 450-8R 49
KOMTRAX Settings (Terminal Status) 3. Contents of display of terminal status

The setting condition and operating condition of On the “Terminal Status” screen, the following
KOMTRAX can be checked with Display of items are displayed.
KOMTRAX setting. q Terminal type: Model name of KOMTRAX
Setting condition of terminal is used to check the communication MODEM
setting condition of the KOMTRAX terminal. q KOMTRAX communication: Executing condi-
tion of station opening inspection
1. Selecting menu q GMT time: Greenwich Meant Time
Select “KOMTRAX Settings” on the “Service q [F5]: Return to KOMTRAX settings screen
Menu” screen.

After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
function switches or numeral input switches.
Service menu screen.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is dis-
played.
50 PC400, 450-8R
KOMTRAX Settings (GPS & Communication Sta- 3. Contents of display of GPS & communication
tus) status
The setting condition and operating condition of On the screen of “GPS & Communication
KOMTRAX can be checked with “KOMTRAX Status”, the following items are displayed.
Settings”. q Positioning: Positioning condition of GPS
GPS & communication status is used to check the q Communication: Communication environ-
condition of positioning and communication of the ment of communication MODEM and con-
KOMTRAX terminal. necting condition of communication MODEM
q Number of message not yet sent: Number of
1. Selecting menu mails which are saved in machine monitor
Select “KOMTRAX Settings” on the “Service and not transmitted yet
Menu” screen. q [F5]: Return to KOMTRAX settings screen

displayed, select GPS & communication status
with the function switches or numeral input
switches.
a The following figure shows the display when
Model TH300 KOMTRAX is installed. When
TH200 is installed, “03 IP Adress” is dis-
played.
PC400, 450-8R 51
KOMTRAX Setting (MODEM S/N: TH300) 3. Contents of display of Modem S/N

The setting condition and operating condition of The serial No. of TH300 Modem is displayed.
KOMTRAX can be checked with Display of q [F5]: Return to KOMTRAX settings screen
KOMTRAX setting.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1. Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

displayed, select “Modem S/N” with the function
52 PC400, 450-8R
KOMTRAX Settings (IP Address: TH200) 3. Contents of display of IP address

The setting condition and operating condition of The telephone No. and IP address (2 systems)
KOMTRAX can be checked with Display of of TH200 MODEM are displayed.
KOMTRAX settings. q [F5]: Return to KOMTRAX setting screen
IP address is used to check the IP address of the a The IP address is a No. specific to each MO-
KOMTRAX communication MODEM. DEM which is required when communication
is made between the MODEM and the serv-
1. Selecting menu er.
Select "KOMTRAX Settings" on the service
menu screen.

displayed, select “IP Address” with the function
PC400, 450-8R 53
Display of KOMTRAX message 3. Display of message (with return mail function)

Special messages for the serviceman sent from the If a box to enter a value with the numeral keys is
KOMTRAX base station (a distributor, etc.) can be displayed under the message, enter a proper
checked with this function. number with the numeral input switches and
If there is setting in a message, a return mail can be function switches and confirm it, and the infor-
sent by using numeral input switches. mation is returned to the KOMTRAX base
station.
1. Operation to display menu q [F5]: Return to service menu screen
Select "Service message" on the service menu q [F6]: Confirm and return input value
screen. a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the service-
man, the message monitor is not displayed
when it is received as in the operator mode.
2. Display of message (Read-only)

If there is a message, its contents are displayed.
If there is not a message, "No message" is
displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the service-
man, the message monitor is not displayed
when it is received as in the operator mode.
54 PC400, 450-8R
PC400, 450-8R 55
©2010 KOMATSU
All Rights Reserved
56
SEN04260-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
30 Testing and adjusting 1

Handling voltage circuit of engine controller ................................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Pm Clinic service ............................................................................................................................................ 9
PC400, 450-8R 1
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.
2 PC400, 450-8R
Preparation work for 4) Insert or connect troubleshooting T-adapt-

troubleshooting of electrical ers in or to connectors CM01, CM02, and
CM03 of machine monitor (4).
system 1 a Connectors CM02 and CM03 are of
a When carrying out troubleshooting of an elec- the same type. When returning them,
tric circuit related to the machine monitor, check the mark plates of the mount-
e n g i n e c o n t r o l l e r, p u m p c o n t r o l l e r, o r ing brackets and take care not to
KOMTRAX communication MODEM, expose make a wrong connection.
the related connectors according to the follow-
ing procedure.
a Disconnect and connect the connectors having
special locking mechanisms according to the
procedure shown below.
1. Machine monitor
1) Remove 2 mounting bolts and cover (1).
a One of the mounting bolts is installed
in the cover on the right of the day-
light sensor.
a While removing the mounting bolts,
disconnect connector P31 of the day-
light sensor.
2) Remove cover (2).
a The cover is fixed with clips. Remove 2. Engine controller
it by pull it up. 1) Open the engine hood cover on the con-
a While removing the cover, discon- trol valve side.
nect connector M04 of the cigarette 2) Remove cover (1).
lighter.
3) Insert or connect troubleshooting T-adapt-

3) Remove 1 mounting bolt and duct (3). 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}
PC400, 450-8R 3
7) Connect the troubleshooting adapters to

connectors C01 and C02 of pump control-
ler (12).
a Install the adapters to only the wiring
harness side.
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove the 5 mounting bolts and cool &
hot box (6).
a While removing the cool & hot box, a The connectors of the pump control-
disconnect the drain hose. ler have a special locking mecha-
3) Remove the 2 mounting bolts, 1 fastener, nism. Disconnect them according to
and magazine box (7). steps (a) – (c) and connect them
4) Remove the 3 mounting bolts and cover according to steps (d) – (f) as shown
(8). below.
5) Remove fuse box cover (9) and cover Disconnection: (a) Unlock – (b)
(10). Slide lever – (c) Disconnect connec-
a Since the underside of cover (10) is tor.
clamped, pull it up. Connection: (d) Position connector –
6) Remove the 7 mounting bolts and cover (e) Slide lever – (f) Lock.
(11).
4 PC400, 450-8R
4. KOMTRAX communication module 5. Atmospheric pressure sensor (AMBAIR

1) Slide the operator's seat and seat stand to PRESSURE)
the forward end. Engine Ne speed sensor (CRANK SENSOR)
2) Remove the 5 mounting bolts and cool & Engine Bkup speed sensor (CAM SENSOR)
hot box (6). Engine oil pressure switch (OIL PRESSURE
a While removing the cool & hot box, SWITCH)
disconnect the drain hose. a Disconnection and connection of con-
3) Remove the 2 mounting bolts, 1 fastener, nectors
and magazine box (7). The connectors of the atmospheric pres-
4) Remove the 3 mounting bolts and cover sure sensor, engine Ne speed sensor,
(8). engine Bkup speed sensor, engine oil
5) Remove fuse box cover (9) and cover pressure switch have a special locking
(10). mechanism. Disconnect them according
a Since the underside of cover (10) is to steps (a) – (c) and connect them
clamped, pull it up. according to steps (d) – (f) as shown
6) Remove the 7 mounting bolts and cover below.
(11). Disconnection: (a) Slide lever – (b)
Unlock – (c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
7) Connect troubleshooting T-adapters to con-

nectors CK01 and CK02 of KOMTRAX
communication module (13).
a Removal and installation of sensor
a Cable (14) is for the communication
A deep socket is necessary for removal
antenna.
and installation of the engine oil pressure
switch. See "Tools for testing, adjusting,
and troubleshooting".
PC400, 450-8R 5
6. Boost pressure and temperature sensor a Precautions for disconnecting connector

(BOOST PRESS & IMT) The direction of the lock of the connector
a Disconnection and connection of con- varies with the tightened position of the
nector sensor and the lock may be in a direction
The connector of the boost pressure and in which it is difficult to reset (on the under-
temperature sensor has a special locking side or engine side).
mechanism. Disconnect it according to In this case, pinch the lock in direction (a)
steps (a) – (b) and connect it according to with bent-nose nippers [1] (commercially
steps (c) – (d) as shown below. available), and the lock is reset.
Disconnection: (a) Unlock – (b) Discon- Since the lock clicks when it is reset, dis-
nect connector. connect the connector after a click is heard.
Connection: (c) Connect connector – (d)
Lock.
a Precautions for connecting connector

Take care not to connect the connector
reversely.
a Removal and installation of sensor Engage lock (e) on the wiring harness side
A torque wrench is necessary for removal with triangular notch (f) on the sensor side
and installation of the boost pressure and (Do not engage lock (e) with square guide
temperature sensor. See "Tools for test- (g) on the opposite side of triangular notch
ing, adjusting, and troubleshooting". (f)).
7. Supply pump IMV solenoid (FUEL REGULATOR)

a Disconnection and connection of con-
nector
The connector of the supply pump IMV
solenoid has a special locking mecha-
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.
6 PC400, 450-8R
8. Common rail pressure sensor (FUEL RAIL 9. Engine coolant temperature sensor (COOL-
PRESS) ANT TEMP)
a Disconnection and connection of con- a Disconnection and connection of con-
nector nector
The connector of the common rail pres- The connector of the engine coolant tem-
sure sensor has a special locking mecha- perature sensor has a special locking
nism. Disconnect it according to steps (a) mechanism. Disconnect it according to
– (b) and connect it according to steps (c) steps (a) – (b) and connect it according to
– (d) as shown below. steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Discon- Disconnection: (a) Unlock – (b) Discon-
nect connector. nect connector.
Connection: (c) Connect connector – (d) Connection: (c) Connect connector – (d)
Lock. 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, 450-8R 7
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.
8 PC400, 450-8R
Pm Clinic service 1
Model name Serial No. Service meter
T PC400-8R
h
T PC450-8R T LC
User's 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 equipment system fault history Electrical equipment system fault history
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
PC400, 450-8R 9
Items related to engine
10 PC400, 450-8R
Items relItems related to oil pressure
PC400, 450-8R 11
12 PC400, 450-8R
PC400, 450-8R 13
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
14 PC400, 450-8R
Undercarriage troubleshooting report 1

(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model PC400/450-8R 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:
PC400, 450-8R 15
SEN04260-00

© 2008 KOMATSU
All Rights Reserved
16
SEN04262-01
PC400, 450-8R
SEN04262-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
Failure code table and fuse locations
Failure codes table...................................................................................................................................... 2

Fuse locations............................................................................................................................................. 5
PC400, 450-8R 1
SEN04262-01 40 Troubleshooting
Failure codes table

Device in Reference
charge document No.
— A000N1 Eng. Hi Out of Std MON Mechanical system
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low MON Mechanical system
— B@BAZK Eng. Oil Level Low ENG Mechanical system
— B@BCNS Eng. Water Overheat MON Mechanical system
— B@BCZK Eng. Water Lvl Low ENG Mechanical system
E02 B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
Eng Ne and Bkup Speed Sens
E10 CA115 ENG Electrical system
Error
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
Troubleshooting
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
by failure code
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system (Display of code),
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system Part 1
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system SEN04264-01
E11 CA221 Ambient Press Sens High Error ENG Electrical system
E11 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
E10 CA271 IMV/PCV1 Short Error ENG Electrical system
E10 CA272 IMV/PCV1 Open Error ENG Electrical system
E10 CA273 PCV2 Short Error ENG Electrical system
E10 CA274 PCV2 Open Error ENG Electrical system
E10 CA342 Calibration Code Incompatibility ENG Electrical system
Troubleshooting
E10 CA351 Injectors Drive Circuit Error ENG Electrical system by failure code
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system (Display of code),
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system Part 2
SEN04265-01
E10 CA441 Battery Voltage Low Error ENG Electrical system
2 PC400, 450-8R
Device in Reference
charge document No.
E10 CA442 Battery Voltage High Error ENG Electrical system
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
E11 CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Ne Speed Sensor Error ENG Electrical system
E15 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E15 CA778 Bkup Speed Sensor Error ENG Electrical system Troubleshooting
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system by failure code
(Display of code),
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
Part 2
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system SEN04265-01
E11 CA2249 Rail Press Very 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
5V sensor power supply output 1
E02 DA25KP PUMP Electrical system
abnormality
CAN discon
E0E DA2RMC PUMP Electrical system
(Pump con detected)
— DA2SKQ Model Selection Abnormality PUMP Electrical system
CAN discon
E0E DAFRMC PUMP Electrical system
(Monitor detected)
— DHPAMA F Pump P. Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump P. Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Sen. Abnormality PUMP Electrical system
— DW43KA Travel Speed Sol. Disc. PUMP Electrical system
— DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C PUMP Electrical system Troubleshooting
— DW91KA Travel Junction Sol. Disc. PUMP Electrical system by failure code
— DW91KB Travel Junction Sol. S/C PUMP Electrical system (Display of code),
Part 3
— DWJ0KA Merge-divider Sol. Disc PUMP Electrical system SEN04266-01
— DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
— DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
— DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
— DXE0KB LS-EPC Sol. S/C PUMP Electrical system
— DXE4KA Service Current EPC Disc. PUMP Electrical system
— DXE4KB Service Current EPC S/C PUMP Electrical system
PC400, 450-8R 3
Device in Reference
charge document No.
— DY20KA Wiper Working Abnormality PUMP Electrical system
Troubleshooting
— DY20MA Wiper Parking Abnormality PUMP Electrical system by failure code
— DY2CKB Washer Drive Short PUMP Electrical system (Display of code),
— DY2DKB Wiper Drive (For) Short PUMP Electrical system Part 3
SEN04266-01
— DY2EKB Wiper Drive (Rev) Short PUMP Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
4 PC400, 450-8R
Fuse locations
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible
links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10A Work lamp relay, emergency switch
2 30A Solenoid valve
F04 3 10A PPC oil pressure lock solenoid valve

Switch power supply
(65A) Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Auto preheater
7 10A Beacon
F04 8 20A Working lamp (boom), working lamp (rear)

Switch power supply
(65A) Radio, speaker
9 10A
Left knob switch (pump controller input)
10 20A (Spare)
11 20A Air conditioner unit
12 10A (Spare)
13 10A Headlamp
F04
Switch power supply
(65A) 14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 20A Optional power supply (2), heated seat, air suspension
seat
Radio (backup power supply)
16 10A
Room lamp
Constant power sup- F05 Pump controller

17 20A
ply (30A) Machine monitor
18 10A Electric priming pump
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
PC400, 450-8R 5
Location of fuse box and fuse Nos.
6 PC400, 450-8R
PC400, 450-8R 7
©2009 KOMATSU
All Rights Reserved
8
SEN04263-01
PC400, 450-8R
SEN04263-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting ................................................................................................. 2

Sequence of events in troubleshooting ....................................................................................................... 3
Check 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, 450-8R 1
Points to remember when troubleshooting

k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely 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, al-
ways 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, and important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry 4) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
q Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or as
q It will become impossible to find the cause of a problem with the method of operation, etc.
the failure. a When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. For this make the problem worse.
reason, when carrying out troubleshooting, it is
necessary to carry out thorough prior investiga- 5. Troubleshooting
tion and to carry out troubleshooting in accor- Use the results of the investigation and inspec-
dance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is as
2) Was there anything strange about the follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were there 2] Start from the most likely points.
problems with the machine condition before 3] Investigate other related parts or informa-
this? tion.
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? When were these repairs carried Even if the failure is repaired, if the root cause of
out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred occur again.To prevent this, always investigate
before? why the problem occurred. Then, remove the
root cause.
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 PC400, 450-8R
Sequence of events in troubleshooting

(Rev. 2007. 12)
PC400, 450-8R 3
Check before troubleshooting
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 cor-
― Retighten or replace
rosion
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
1. Check for abnormal noise and smell ― Repair
Hydrau-
lic/Mechani- 2. Check for oil leakage ― Repair
cal 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 cover ― Replace
4. Check for released wire clamp and drooping wire ― Repair

Electric, elec-
trical equip- 5. Check of wires for wetness (Check connectors and termi- ―
Disconnect the con-
ment nals for wetness, in particular) nectors and dry
6. Check of fuse for disconnection and corrosion ― Replace
After operating for
7. Check of alternator voltage (while engine speed is at middle
several minutes: Replace
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, 450-8R
Classification and troubleshooting steps

Classification for 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 [ ] switch at panel switch section to display
failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality record
function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then see
if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code is recorded
in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnormality
record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or
hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out trouble-
shooting corresponding to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
PC400, 450-8R 5
Information in troubleshooting table

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code

Trouble name displayed in abnormality record machine
Display on Trouble
Display on machine monitor
machine moni-
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>
q Standard value in normal state to judge possible causes
q Remarks on judgment
1 <Troubles in wiring harness>

q Disconnection
Connector is connected imperfectly or wiring harness is
broken.
q Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
q Hot short
Wiring harness which is not connected to power source
2 (24 V) circuit is in contact with power source (24 V) circuit.
q Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes
and standard Possible causes of trouble
value in normal (Given numbers are reference
<Precautions for troubleshooting>
state numbers, which do not indi-
(1) Method of indicating connector No. and handling of
cate priority)
T-adapter
Insert or connect T-adapter as explained below for trou-
bleshooting, unless otherwise specified.
3
q If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both
male side and female side.
q If connector No. has marks of “male” and “female”,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 q Connect positive (+) lead to pin No. or wiring harness
entered on front side.
q Connect negative (–) lead to pin No. or harness en-
tered on rear side.
6 PC400, 450-8R
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trou-

bleshooting.
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 with-
in the parts of the same wiring harness.
q Arrow (io): Roughly shows the location on the machine.
PC400, 450-8R 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 displayed According to
2 displayed
in electrical system abnormality record
When abnormality record is checked, failure code is displayed code
3
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 does Engine rotates, but exhaust gas does not come
6 S-2 (2)
not start out
7 Engine emits exhaust gas, but it does not start S-2 (3)
Engine does not pick up smoothly (follow-up performance is
8 S-3
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
16 Oil is in coolant, coolant spurts back or coolant level goes down S-11
17 Oil level rises (Entry of coolant or fuel) S-13
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Auto-decelerator does not operate E-2 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 swing is
23 H-1 S-6
low
24 Engine speed lowers extremely or engine stalls H-2 S-4
25 Work equipment, swing, and travel mechanism do not move E-5 H-3
26 Abnormal sound comes out from around hydraulic pump H-4
27 Fine control performance or response is low H-6
Phenomena related to work equipment
28 Speed or power of boom is low E-18, 19 H-7
29 Speed or power of arm is low E-20, 21 H-8
30 Speed or power of bucket is low E-22, 23 H-9
31 Boom, arm, or bucket does not move H-10
32 Hydraulic drift of work equipment is large H-11
8 PC400, 450-8R
Troubleshooting
code
33 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts of
34 H-13
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-15
loaded more is low
When machine swings and raises boom simultaneously, boom
37 H-16
rising speed is low
When work equipment and travels simultaneously, travel speed
38 H-17
lowers largely
Phenomena related to travel
39 Machine deviates during travel H-18
40 Travel speed is low E-25 H-19
41 Machine is not steered well or steering power is low E-25, 26 H-20
42 Travel speed does not change or travel speed is low or high E-25 H-21
43 Travel system does not move (only one side) H-22
Phenomena related to swing
44 Upper structure does not swing E-24 H-23
45 Swing acceleration or swing speed is low H-24
46 Upper structure overruns remarkably when it stops swinging H-25
47 Large shock is made when upper structure stops swinging H-26
48 Large sound is made when upper structure stops swinging H-27
49 Hydraulic drift of swing H-28
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 appli-
52 E-9
cable machine
Radiator coolant level monitor lights up in red during check
53 B@BCZK
before starting
Engine oil level monitor lights up in red during check before
54 B@BAZK
starting
Maintenance interval monitor lights up in red during check
55 See the Operation and Maintenance Manual.
before starting
56 Charge level monitor lights up in red while engine is running AB00KE
57 Fuel level monitor lights up in red while engine is running E-10
Air cleaner clogging monitor lights up in red while engine is run-
58 AA10NX
ning
Engine coolant temperature monitor lights up in red while
59 B@BCNS
engine is running
Hydraulic oil temperature monitor lights up in red while engine
60 B@HANS
is running
61 Engine coolant temperature gauge does not indicate normally E-11
PC400, 450-8R 9
Troubleshooting
code
62 Hydraulic oil temperature gauge does not indicate normally E-12
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 mon-
65 E-15
itor switch section
66 Windshield wiper does not operate E-16
67 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
68 Monitoring function does not display “Boom RAISE” normally E-18
69 Monitoring function does not display “Boom LOWER” normally E-19
70 Monitoring function does not display “Arm IN” normally E-20
71 Monitoring function does not display “Arm OUT” normally E-21
72 Monitoring function does not display “Bucket CURL” normally E-22
73 Monitoring function does not display “Bucket DUMP” normally E-23
74 Monitoring function does not display “Swing” normally E-24
75 Monitoring function does not display “Travel” normally E-25
76 Monitoring function does not display “Travel Steering” normally E-26
77 Monitoring function does not display “Service” normally E-27
Phenomena related to KOMTRAX
78 KOMTRAX system does not operate normally E-28
Others
79 Air conditioner does not operate E-29
80 Travel alarm does not sound or does not stop sounding E-30
81 Horn does not sound E-31
10 PC400, 450-8R
Connection table for connector pin numbers

(Rev.2009.04)
a The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
PC400, 450-8R 11
12 PC400, 450-8R
PC400, 450-8R 13
14 PC400, 450-8R
PC400, 450-8R 15
16 PC400, 450-8R
PC400, 450-8R 17
18 PC400, 450-8R
PC400, 450-8R 19
20 PC400, 450-8R
PC400, 450-8R 21
22 PC400, 450-8R
PC400, 450-8R 23
24 PC400, 450-8R
PC400, 450-8R 25
26 PC400, 450-8R
PC400, 450-8R 27
28 PC400, 450-8R
PC400, 450-8R 29
30 PC400, 450-8R
PC400, 450-8R 31
32 PC400, 450-8R
PC400, 450-8R 33
34 PC400, 450-8R
PC400, 450-8R 35
36 PC400, 450-8R
PC400, 450-8R 37
38 PC400, 450-8R
PC400, 450-8R 39
40 PC400, 450-8R
PC400, 450-8R 41
42 PC400, 450-8R
PC400, 450-8R 43
44 PC400, 450-8R
PC400, 450-8R 45
46 PC400, 450-8R
T- branch box and T- branch adapter table

(Rev.2009.03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn 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, 450-8R 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, 450-8R
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*
Socket for engine (CRI-T3) PCV
2 P q q
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*
Socket for engine (CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
Adapter for engine (CRI-T3) NE,
799-601-4130
CAM
3 FCIN q q
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1,2,3L q q
799-601-4230*
Air intake pressure/temperature
4 1,2,3,4C q q
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*
Pump actuator
2 2,PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1,2,3,4T q
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,
799-601-9890 Multi-adapter for DT2 – 4 andDTM2 3, — q
4
"*" Shows not T-adapter but socket.
PC400, 450-8R 49
©2009 KOMATSU
All Rights Reserved
50
SEN04264-02
PC400, 450-8R
SEN04264-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
Troubleshooting by failure code
(Display of code), Part 1
Failure code [AA10NX] Air cleaner 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 Level Low........................................................................................... 14
Failure code [B@HANS] Hydr Oil Overheat ............................................................................................... 16
Failure code [CA111] EMC Critical Internal Failure..................................................................................... 17
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................ 17
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................. 18
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................................. 20
Failure code [CA131] Throttle Sensor High Error ....................................................................................... 22
Failure code [CA132] Throttle Sensor Low Error ........................................................................................ 24
Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................. 26
Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................................. 28
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
PC400, 450-8R 1
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.................................................................................. 44
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 ..................................................................................................... 56
Failure code [CA322] Inj #1 Open/Short Error ............................................................................................ 58
2 PC400, 450-8R
PC400, 450-8R 3
Failure code [AA10NX] Air cleaner Clogging

User code Failure code Air cleaner clogging
Trouble
(Machine monitor system)
— AA10NX
Contents of q While engine was running, signal circuit of air cleaner clogging switch detected clogging of air
trouble cleaner (sensor contact opened).
Action of con- q Displays air cleaner clogging monitor on machine monitor.
troller q If cause of failure disappears, system resets itself.
Problem that
appears on q If machine is operated as it is, engine may be damaged.
machine
q Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related infor-
(Code: 04501 Monitor input 2)
mation
q Method of reproducing failure code: Start engine.

Clogging of air cleaner a Check the air cleaner for clogging and then clean or replace it if
1
(when system is normal) clogged.
a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective air cleaner clog-
P23 (male) Air cleaner Resistance
2 ging switch
(internal disconnection) Value in normal state Max. 1 Ω
Between (1) – (2)
Value when clogged Min. 1 MΩ
Possible causes
and standard a Prepare with starting switch OFF, then start engine and carry
Disconnection in wiring har- out troubleshooting.
value in normal
ness
state Wiring harness between CM02 (female) (4) Resis-
3 (Disconnection in wiring or Max. 1 Ω
– P23 (female) (1) tance
defective contact in connec-
Wiring harness between P23 (female) (2) – Resis-
tor) Max. 1 Ω
chassis ground tance
CM02 Air cleaner Voltage
4 Defective machine monitor
Between (4) – chas- Value in normal state Max. 1 V
sis ground Value when clogged 20 – 30 V
4 PC400, 450-8R
Circuit diagram related to air cleaner clogging switch of machine monitor
PC400, 450-8R 5
Failure code [AB00KE] Charge Voltage Low

User code Failure code Charge voltage low
Trouble
— AB00KE
Contents of
q While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble
Action of con- q Displays charge level monitor on machine monitor.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on q If machine is operated as it is, battery may not be charged.
machine
q Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge volt-
Related infor-
age)
mation

Defective alternator
1 Alternator Engine speed Voltage
(Low power generation)
R terminal – chassis
Min. medium speed 27.5 – 29.5 V
ground
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
2 (Disconnection in wiring or
Wiring harness between CM01 (female) (11) Resis-
Possible causes defective contact in connec- Max. 1 Ω
– J02 – Alternator R terminal tance
and standard tor)
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Ground fault in wiring har-
Wiring harness between CM01 (female) (11)
ness
3 – J02 – Alternator R terminal, between P02
(Short circuit with GND cir- Resis-
(female) (11) – J02 – D01 (female) (6) and Min. 1 MΩ
cuit) tance
between P02 (female) (11) – J02 – M17
(female) (2) and chassis ground
4 Defective machine monitor CM01 Engine speed Voltage
Between (11) – chas-
Min. medium speed 27.5 – 29.5 V
sis ground
6 PC400, 450-8R
Circuit diagram related to starting and charge of machine monitor
PC400, 450-8R 7
Failure code [B@BAZG] Eng Oil Press. Low

User code Failure code Engine oil pressure low
Trouble
(Engine controller system)
— B@BAZG
Contents of q While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (sensor contact opened).
Action of con- q Displays engine oil pressure monitor on machine monitor.
Problem that
machine
q Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon-
Related infor-
itor.
mation
q Method of reproducing failure code: Start engine

Lowering of engine oil pres-
a Determine the cause and check the damage to the engine and
1 sure
then modify it.
(when system is normal)
Defective engine oil pres-
POIL (male) Engine Resistance
2 sure sensor
(Internal defect) Between (3) – chas- When started Min. 1 MΩ
sis ground When stopped Max. 1 Ω
Possible causes ness without turning starting switch ON.
and standard 3 (Disconnection in wiring or
value in normal Wiring harness between CE01 (female) (13) Resis-
defective contact in connec- Max. 1 Ω
state – POIL (female) (3) tance
tor)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ness
4 Wiring harness between CE01 (female) (13)
– POIL (female) (3) and chassis ground Min. 1 MΩ
cuit) tance
(when engine is started)
CE01 Engine Resistance
5 Defective engine controller
Between (13) – chas- When started Min. 1 MΩ
sis ground When stopped Max. 1 Ω
8 PC400, 450-8R
Circuit diagram related to engine oil pressure of machine monitor
PC400, 450-8R 9
10 PC400, 450-8R
Failure code [B@BAZK] Eng Oil Level Low

User code Failure code Engine oil level low
Trouble
— B@BAZK
Contents of q 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 con- q Displays engine oil level monitor on machine monitor.
Problem that
machine
q Engine oil level switch signal can be checked with monitoring function.
Related infor-
(Code 04501: Monitor Input 2)
mation
q Method of reproducing failure code: Turn starting switch ON.

Lowering of engine oil level a Check the engine oil level and add new oil.
1
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
Defective engine oil level P44 (male) Engine oil level Resistance
2 switch
(Internal disconnection) Value in normal state Max. 1 Ω
sis ground Value when oil level
Possible causes Min. 1 MΩ
is low
and standard
value in normal
state
Wiring harness between CM02 (female) (2) Resis-
tor)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CM02 Engine oil level Voltage
Value in normal state Max. 1 V
sis ground Value when oil level
20 – 30 V
is low
Circuit diagram related to engine oil level switch of machine monitor
PC400, 450-8R 11
Failure code [B@BCNS] Eng. Water Overheat

User code Failure code Engine coolant overheat
Trouble
— B@BCNS
Contents of q While engine was running, signal circuit of engine coolant temperature sensor detected overheat-
trouble ing of engine coolant (above about 102 °C).
Action of con- q Displays engine coolant temperature monitor with red on machine monitor.
Problem that
appears on q If machine is operated as it is, engine may seize up.
machine
q Engine coolant temperature sensor signal is input to engine controller and then transmitted to ma-
chine monitor.
Related infor-
q Engine coolant temperature can be checked with monitoring function
mation
(Code: 04107 Engine coolant temperature)

Possible causes Overheating of engine cool- Engine coolant may be overheating. Check it and remove cause if
and standard 1
ant (when system is normal) it is overheating.
value in normal
If cause 1 is not detected, engine coolant temperature gauge sys-
state Defective engine coolant
2 tem may be defective. Carry out troubleshooting for "[CA144]
temperature gauge system
[CA145]" in troubleshooting.
12 PC400, 450-8R
Circuit diagram related to engine coolant temperature sensor of machine monitor
PC400, 450-8R 13
Failure code [B@BCZK] Eng Water Level Low

User code Failure code Engine coolant level low
Trouble
— B@BCZK
Contents of q When starting switch is turned ON, signal circuit of radiator coolant level sensor detected low radi-
trouble ator coolant level (sensor contact opened).
Action of con- q Displays radiator coolant level monitor on machine monitor.
troller q Even if cause of failure disappers, system does not reset itself until starting switch is turned OFF.
Problem that
appears on q If machine is operated as it is, engine may overheat.
machine
q Condition of radiator coolant level switch can be checked with monitoring function
Related infor-
(Code: 04500 Monitor input 1)
mation

Lowering of radiator coolant
a Check the coolant level and add coolant.
1 level
(If this phenomenon frequently occurs, investigate the cause.)
(when system is normal)
Defective radiator coolant P24 (male) Radiator coolant level Resistance
2 level switch (internal discon-
nection) Value in normal state Max. 1 Ω
Between (1) – (2) Value when coolant
Min. 1 MΩ
Possible causes level is low
and standard a Prepare with starting switch OFF, then carry out troubleshooting
Disconnection in wiring har- without turning starting switch ON.
value in normal
ness
state Wiring harness between P02 (female) (3) – Resis-
P24 (female) (1) tance
tor) Max. 1 Ω
Engine coolant tem-
P02 Voltage
4 Defective machine monitor perature
Value in normal state Max. 1 V
sis ground Value when coolant
20 – 30 V
level is low
14 PC400, 450-8R
Circuit diagram related to radiator coolant level switch of machine monitor
PC400, 450-8R 15
Failure code [B@HANS] Hydr Oil Overheat

User code Failure code Hydraulic oil overheat
Trouble
(Pump controller system)
— B@HANS
Contents of q While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating
trouble of hydraulic oil (above about 102 °C).
Action of con- q Displays hydraulic oil temperature monitor with red on machine monitor.
Problem that
appears on q If machine is operated as it is, engine may be seized.
machine
q Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to ma-
chine monitor.
Related infor-
q Hydraulic oil temperature can be checked with monitoring function
mation
(Code: 04401 Hydraulic oil temperature)

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it
and standard 1
(when system is normal) is overheating.
value in normal
If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for "E-12 Hydraulic oil
perature gauge system
temperature gauge does not work normally" in E-mode.
Circuit diagram related to hydraulic oil temperature sensor of machine monitor
16 PC400, 450-8R
Failure code [CA111] EMC Critical Internal Failure

User code Failure code EMC critical internal failure
Trouble
E10 CA111
Contents of
q Memory or power supply circuit in engine controller is defective.
trouble
Action of con-
q None in particular.
troller
Problem that
appears on q Engine does not start.
machine
Related infor-
mation
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Engine controller may be defective. (Since trouble is in system,
state troubleshooting cannot be carried out.)
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

User code Failure code Engine Ne and Bkup speed sensor error
Trouble
E10 CA115
Contents of
q Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
trouble
Action of con-
troller
Problem that
q Engine stops.
appears on
q Engine does not start.
machine
Related infor-
mation

and standard Connectors of Ne speed sensor and Bkup speed sensor may be
value in normal Defective connection of sen-
1 connected defectively (or connected to wrong parts). Check them
state sor connector
directly.
PC400, 450-8R 17
Failure code [CA122] Chg Air Press Sensor High Error

User code Failure code Charge air pressure sensor high error
Trouble
E11 CA122
Contents of
q Pressure signal circuit of boost pressure sensor detected high voltage.
trouble
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem that
appears on q Engine output lowers.
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.
PIM (male) Voltage
Defective boost pressure
2 sensor [pressure signal sys- Between (2) – (3) Power supply 4.75 – 5.25 V
tem]
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 CE01 (female) (44)
cuit) Voltage Max. 1 V
and standard – PIM (female) (2) and chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between CE01 (female) (44)
Resis- Min.
(with another wiring harness) – PIM (female) (2) and between CE01
tance 100 kΩ
(female) (37) – PIM (female) (1)
Connecting parts between boost pressure sensor – engine wiring

harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 q Looseness of connector, breakage of lock, or breakage of seal
connector
q Corrosion, bend, breakage, push-in, or expansion of pin
q Moisture or dirt in connector or defective insulation

6 Defective engine controller CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
18 PC400, 450-8R
Circuit diagram related to boost pressure sensor
PC400, 450-8R 19
Failure code [CA123] Chg Air Press Sensor Low Error

User code Failure code Charge air pressure sensor low error
Trouble
E11 CA123
Contents of
q Pressure signal circuit of boost pressure sensor detected low voltage.
trouble
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem that
machine
Related infor-
mation

1
PIM (male) Voltage
Defective boost pressure
2 sensor [pressure signal sys- Between (2) – (3) Power supply 4.75 – 5.25 V
tem]
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard ness without turning starting switch ON.
3
value in normal (Short circuit with GND cir- Wiring harness between CE01 (female) (44) Resis- Min.
state cuit) – PIM (female) (2) and chassis ground tance 100 kΩ
Short circuit in wiring har- without turning starting switch ON.
(with another wiring harness) – PIM (female) (2) and between CE01 Resis- Min.
tance 100 kΩ
(female) (47) – PIM (female) (3)
Connecting parts between boost pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
connector

CE01 Voltage
20 PC400, 450-8R
Circuit diagram related to boost pressure sensor
PC400, 450-8R 21
Failure code [CA131] Throttle Sensor High Error

User code Failure code Throttle sensor high error
Trouble
E14 CA131
Contents of
q Signal circuit of fuel control dial detected high voltage.
trouble
q 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 q If starting switch is turned ON while voltage is abnormally high, controller continues operation with
voltage at 100% value.
Problem that
appears on q Engine speed cannot be controlled with fuel control dial.
machine
q Signal voltage of fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation

Defective throttle sensor If failure code [CA2185] is also indicated, carry out troubleshooting
1
power supply system for it first.
P20 (male) Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Hot short in wiring harness and carry out troubleshooting.
Possible causes 3 (Short circuit with 5V/24V cir-
and standard Wiring harness between CE02 (female) (9)
cuit) Voltage Max. 1 V
value in normal – P20 (female) (2) and chassis ground
state a Prepare with starting switch OFF, then carry out troubleshooting
Resis- Min.
(with another wiring harness) – P20 (female) (2) and between CE02
tance 100 kΩ
(female) (22) – P20 (female) (1)
Connecting parts between fuel control dial – machine wiring har-
ness – engine controller may be defective. Check them directly.
connector
22 PC400, 450-8R
Circuit diagram related to fuel control dial
PC400, 450-8R 23
Failure code [CA132] Throttle Sensor Low Error

User code Failure code Throttle sensor low error
Trouble
E14 CA132
Contents of
q Signal circuit of fuel control dial detected low voltage.
trouble
Problem that
machine
q Signal voltage of fuel control dial can be checked with monitoring function.
Related infor-
(Code: 03000 Fuel control dial voltage)
mation

Defective throttle sensor If failure code [CA2186] is also indicated, carry out troubleshooting
1
P20 (male) Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes 3
and standard (Short circuit with GND cir- Wiring harness between CE02 (female) (9) Resis- Min.
value in normal cuit) – P20 (female) (2) and chassis ground tance 100 kΩ
Resis- Min.
(with another wiring harness) – P20 (female) (2) and between CE02
tance 100 kΩ
(female) (23) – P20 (female) (3)
connector
24 PC400, 450-8R
PC400, 450-8R 25
Failure code [CA135] Eng Oil Press Sensor High Error

User code Failure code Eng Oil Press Sensor High Error
Trouble
E15 CA135
Contents of
q High pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of con-
troller q Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related infor-
mation

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.
POIL Voltage
Defective oil pressure sen-
2 sor Between (1) – (2) Power supply 4.75 – 5.25 V
(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.
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
Max. 1 Ω
ness – POIL (female) (1) tance
Wiring harness between ENG (female) (47) Resis-
– POIL (female) (2) tance
tor)
Max. 1 Ω
– POIL (female) (3) tance
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Ground fault in wiring har- Between wiring harness of ENG (female) Resis-
state Min. 1 MΩ
ness (37) – POIL (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Between wiring harness of ENG (female) Resis-
Min. 1 MΩ
cuit) (47) – POIL (female) (2) and chassis ground tance
Between wiring harness of ENG (female) Resis-
Min. 1 MΩ
(13) – POIL (female) (3) and chassis ground tance
Wiring harness between ENG (female) (37)
Resis-
– POIL (female) (1) and between ENG Min. 1 MΩ
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
5 ness Wiring harness between ENG (female) (37)
Resis-
(with another wiring harness) – POIL (female) (1) and between ENG Min. 1 MΩ
tance
(female) (13) – POIL (female) (3)
Resis-
– POIL (female) (2) and between ENG Min. 1 MΩ
tance
(female) (13) – POIL (female) (3)
or start engine and carry out troubleshooting.
6 Defective engine controller ENG Voltage
26 PC400, 450-8R
Circuit diagram related to oil pressure sensor
PC400, 450-8R 27
28 PC400, 450-8R
Failure code [CA141] Eng Oil Press Sensor Low Error

User code Failure code Eng Oil Press Sensor Low Error
Trouble
E15 CA141
Contents of
q Low pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of con-
troller q Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related infor-
mation

and standard
value in normal Carry out troubleshooting for failure code [CA135].
state
PC400, 450-8R 29
Failure code [CA144] Coolant Temp Sens High Error

User code Failure code Coolant temperature sensor high error
Trouble
E15 CA144
Contents of
q Signal circuit of coolant temperature sensor detected high voltage.
trouble
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that
q Exhaust gas becomes white.
appears on
Overheat prevention function does not work.
machine
Related infor-
mation

Defective coolant tempera-
1 TWTR (male) Resistance
ture sensor
Between (A) – (B) 0.18 – 160 kΩ
ness Wiring harness between CE01 (female) (15) Resis-
2 (Disconnection in wiring or – TWTR (female) (A) Max. 10 Ω
tance
Wiring harness between CE01 (female) (38) Resis-
tor) Max. 10 Ω
– TWTR (female) (B) tance
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
state 3 ness Between CE01 (female) (15) – each of
Resis- Min.
(with another wiring harness) CE01 (female) pins (With all wiring harness
tance 100 kΩ
connectors disconnected)
Connecting parts between coolant temperature sensor – engine
wiring harness – engine controller may be defective. Check them
Defective wiring harness directly.
4
connector q Looseness of connector, breakage of lock, or breakage of seal
5 Defective engine controller CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kΩ
30 PC400, 450-8R
Circuit diagram related to engine coolant temperature sensor
PC400, 450-8R 31
Failure code [CA145] Coolant Temp Sens Low Error

User code Failure code Coolant temperature sensor low error
Trouble
E15 CA145
Contents of
q Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of con-
q Fixes coolant temperature value and continues operation.
troller
Problem that
appears on
q Overheat prevention function does not work.
machine
Related infor-
mation

Defective coolant tempera- TWTR (male) Resistance
1
ture sensor
Between (A) – (B) 0.18 – 160 kΩ
Between (B) – chassis ground Min. 100 kΩ
2
(Short circuit with GND cir- Wiring harness between CE01 (female) (15) Resis- Min.
cuit) – TWTR (female) (A) and chassis ground tance 100 kΩ
Possible causes
and standard
value in normal 3 ness Between CE01 (female) (15) – each of
(with another wiring harness) CE01 (female) pins (With all wiring harness Resis- Min.
state tance 100 kΩ
Connecting parts between coolant temperature sensor – engine
4

Between (15) – (38) 0.18 – 160 kΩ
Between (15) – chassis ground Min. 100 kΩ
32 PC400, 450-8R
PC400, 450-8R 33
Failure code [CA153] Chg Air Temp Sensor High Error

User code Failure code Charge air temperature sensor high error
Trouble
E15 CA153
Contents of
q Temperature signal circuit of boost temperature sensor detected high voltage.
trouble
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work
machine
Related infor-
mation

Defective boost temperature without turning starting switch ON.
1 sensor [temperature signal TIM (male) Resistance
system]
Between (A) – (B) 0.18 – 160 kΩ
ness
– TIM (female) (A) tance
tor) Wiring harness between CE01 (female) (47) Resis-
Max. 10 Ω
– TIM (female) (B) tance
Possible causes
and standard
value in normal
state 3 ness Between CE01 (female) (23) – each of
tance 100 kΩ
Connecting parts between boost temperature sensor – engine wir-
ing harness – engine controller may be defective. Check them
4
CE01 (female) Resistance
Between (23) – (47) 0.18 – 160 kΩ
34 PC400, 450-8R
Circuit diagram related to boost temperature sensor
PC400, 450-8R 35
Failure code [CA154] Chg Air Temp Sensor Low Error

User code Failure code Charge air temperature sensor low error
Trouble
E15 CA154
Contents of
q Temperature signal circuit of boost temperature sensor detected low voltage.
trouble
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem that
appears on
q Engine protection function based on boost temperature does not work
machine
Related infor-
mation

Defective boost temperature
1 sensor [temperature signal TIM (male) Resistance
system] Between (A) – (B) 0.18 – 160 kΩ
Between (A) – chassis ground Min. 100 kΩ
2
cuit) – TIM (female) (A) and chassis ground tance 100 Ω
Possible causes
and standard
value in normal 3 ness Between CE01 (female) (23) – each of
state tance 100 kΩ
Connecting parts between boost temperature sensor – engine wir-
4

Between (23) – (47) 0.18 – 160 kΩ
Between (23) – chassis ground Min. 100 Ω
36 PC400, 450-8R
Circuit diagram related to boost temperature sensor
PC400, 450-8R 37
Failure code [CA187] Sens Supply 2 Volt Low Error

User code Failure code Sensor power supply 2 voltage low error
Trouble
E15 CA187
Contents of
q Low voltage was detected in sensor power supply 2 circuit.
trouble
Action of con- q Fixes charge pressure and charge temperature values and continues operation.
troller q Limits output and continues operation.
Problem that
machine
Related infor-
mation

a Disconnect connector with starting switch OFF, then turn start-
ing switch ON and carry out troubleshooting.
Disconnect sensor Boost pressure sen-
PIM
and wiring harness at sor
right in order and Boost temperature
TIM
carry out operation to sensor
Defective sensor or wiring
1 reproduce trouble. If Common rail pres-
harness PFUEL
“E” of failure code sure sensor
Possible causes goes off when sen-
and standard sor or wiring harness Bkup sensor G
value in normal is disconnected, that
state Engine wiring har-
sensor or wiring har- CE01
ness
ness is defective.
Connecting parts between each sensor – engine wiring harness –
engine controller may be defective. Check them directly.
connector
If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
38 PC400, 450-8R
Circuit diagram related to sensor power supply 2
PC400, 450-8R 39
Failure code [CA221] Ambient Press Sens High Error

User code Failure code Ambient pressure sensor high error
Trouble
E11 CA221
Contents of
q High voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of con-
q Fixes ambient pressure value and continues operation.
troller
Problem that
q Engine output lowers.
appears on
q Engine starting performance becomes deteriorated.
machine
Related infor-
mation

1
PAMB (male) Voltage
Defective ambient pressure
2 Between (1) – (3) Power supply 4.75 – 5.25 V
sensor
Hot short (Short circuit with and carry out troubleshooting.
3 5V/24V circuit) in wiring har-
ness Voltage Max. 1 V
and standard – PAMB (female) (2) and chassis ground
Resis- Min.
(with another wiring harness) – PAMB (female) (2) and between CE01
tance 100 kΩ
(female) (37) – PAMB (female) (1)
Connecting parts between ambient pressure sensor – engine wir-
5
40 PC400, 450-8R
Circuit diagram related to atmospheric pressure sensor
PC400, 450-8R 41
Failure code [CA222] Ambient Press Sens Low Error

User code Failure code Ambient pressure sensor low error
Trouble
E11 CA222
Contents of
q Low voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of con-
troller
Problem that
appears on
q Engine starting performance becomes deteriorated.
machine
Related infor-
mation

1
PAMB (male) Voltage
Defective ambient pressure
sensor
3
Possible causes (Short circuit with GND cir- Wiring harness between CE01 (female) (3) Resis- Min.
and standard cuit) – PAMB (female) (2) and chassis ground tance 100 kΩ
Resis- Min.
(with another wiring harness) – PAMB (female) (2) and between CE01
tance 100 kΩ
(female) (38) – JM03 – PAMB (female) (3)
5
42 PC400, 450-8R
Circuit diagram related to atmospheric pressure sensor
PC400, 450-8R 43
Failure code [CA227] Sens Supply 2 Volt High Error

User code Failure code Sensor power supply 2 voltage high error
Trouble
E15 CA227
Contents of
q High voltage was detected in sensor power supply 2 circuit.
trouble
Action of con- q Fixes charge pressure and charge temperature values and continues operation.
troller q Limits output and continues operation.
Problem that
machine
Related infor-
mation

Possible causes engine controller may be defective. Check them directly.
and standard connector
value in normal
state
If cause 1 is not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
44 PC400, 450-8R
Failure code [CA234] Eng Overspeed

User code Failure code Engine overspeed
Trouble
— CA234
Contents of
q Engine speed exceeded control upper speed limit.
trouble
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem that
appears on q Engine speed fluctuates.
machine
Related infor-
q Method of reproducing failure code: Run engine at high idle.
mation

1 Use of improper fuel Fuel used may be improper. Check it directly.
Possible causes
and standard Machine may be used improperly. Teach operator proper using
2 Improper use
value in normal method.
state
PC400, 450-8R 45
46 PC400, 450-8R
Failure code [CA238] Ne Speed Sens Supply Volt Error

User code Failure code Ne speed sensor supply power voltage error
Trouble
E15 CA238
Contents of
q Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble
Action of con-
q Controls the engine with signal from engine Bkup speed sensor.
troller
Problem that
q Engine does not start easily.
appears on
q Engine hunts.
machine
Related infor-
mation

Disconnect sensor
and wiring harness at
Ne speed sensor NE
right in order and
carry out operation to
Defective sensor or wiring har-
Possible causes 1 reproduce trouble. If
ness
and standard “E” of failure code
value in normal goes off when sen-
state sor or wiring harness
is disconnected, that Engine wiring har-
CE01
sensor or wiring harness
ness is defective.

Defective wiring harness con-
nector
Circuit diagram related to engine Ne speed sensor
PC400, 450-8R 47
Failure code [CA263] Fuel Temp Sensor High Error

User code Failure code Fuel Temp Sensor High Error
Trouble
E11 CA263
Contents of
q High temperature error occurred in fuel temperature sensor circuit.
trouble
Action of con-
q Fixes fuel temperature value at 90°C and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

Defective fuel temperature without turning starting switch ON.
1 sensor TFUEL (male) Fuel temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kΩ
ness Wiring harness between ENG (female) (30) Resis-
Possible causes 2 (Disconnection in wiring or – TFUEL (female) (A) Max. 1 Ω
tance
and standard defective contact in connec-
value in normal Wiring harness between ENG (female) (47) Resis-
tor) Max. 1 Ω
state – TFUEL (female) (B) tance
Ground fault in wiring har- without turning starting switch ON.
ness Wiring harness between ENG (female) (30) Resis-
3 Min. 1 MΩ
(Short circuit with GND cir- – TFUEL (female) (A) and chassis ground tance
cuit) a Prepare with starting switch OFF, then carry out troubleshooting
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kΩ
48 PC400, 450-8R
Circuit diagram related to fuel temperature sensor
PC400, 450-8R 49
Failure code [CA265] Fuel Temp Sensor Low Error

User code Failure code Fuel Temp Sensor Low Error
Trouble
E15 CA265
Contents of
q Low temperature error occurred in fuel temperature sensor circuit.
trouble
Action of con-
q Fixes fuel temperature value at 90°C and continues operation.
troller
Problem that
appears on
machine
Related infor-
mation

and standard
state
50 PC400, 450-8R
Failure code [CA271] IMV/PCV1 Short Error

User code Failure code IMV/PCV1 Short Error
Trouble
E10 CA271
Contents of
q Short circuit was detected in PCV1 circuit of supply pump.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Defective supply pump
PCV1 (male) Resistance
1 PCV1
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 Ω
Between (1), (2) – chassis
Min. 1 MΩ
ground
ness Wiring harness between ENG (female) (4) – Resis-
2 Min. 1 MΩ
(Short circuit with GND cir- PCV1 (female) (1) and chassis ground tance
Possible causes cuit)
Wiring harness between ENG (female) (5) – Resis-
and standard Min. 1 MΩ
PCV1 (female) (2) and chassis ground tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness
Wiring harness between ENG (female) (4) –
3 (Short circuit with 24V cir- Voltage Max. 1 V
PCV1 (female) (1) and chassis ground
cuit)
Voltage Max. 1 V
ENG (female) Resistance
Between (4) – (5) 2.3 – 5.3 Ω
Min. 1 MΩ
ground
Circuit diagram related to supply pump PCV1
PC400, 450-8R 51
Failure code [CA272] IMV/PCV1 Open Error

User code Failure code IMV/PCV1 Open Error
Trouble
E10 CA272
Contents of
q Open error was detected in PCV1 circuit of supply pump.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Defective supply pump PCV1 (male) Resistance
1 PCV1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 Ω
Min. 1 MΩ
ground
2 (Disconnection in wiring or PCV1 (female) (1) Max. 1 Ω
tance
Possible causes Wiring harness between ENG (female) (5) – Resis-
tor) Max. 1 Ω
and standard PCV1 (female) (2) tance
state without turning starting switch ON.
Ground fault in wiring har- Between wiring harness of ENG (female) (4)
Resis- Max.
ness – PCV1 (female) (1) and chassis ground
3 tance 1 MΩ
(Short circuit with GND cir- and chassis ground
cuit) Between wiring harness of ENG (female) (5)
Resis- Max.
– PCV1 (female) (2) and chassis ground
tance 1 MΩ
and chassis ground
Between (4) – (5) 2.3 – 5.3 Ω
Min. 1 MΩ
ground
52 PC400, 450-8R
PC400, 450-8R 53
Failure code [CA273] PCV2 Short Error

User code Failure code PCV2 Short Error
Trouble
E10 CA273
Contents of
q Short circuit was detected in PCV2 circuit of supply pump.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Defective supply pump PCV2 (male) Resistance
1 PCV2
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 Ω
Between (1), (2) and chassis
Min. 1 MΩ
ground
2 Min. 1 MΩ
Possible causes cuit)
and standard Min. 1 MΩ
– PCV2 (female) (2) and chassis ground tance
value in normal
Hot short in wiring harness
3 (Short circuit with 24V cir- Voltage Max. 1V
cuit)
Voltage Max. 1V
– PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 Ω
Min. 1 MΩ
ground
54 PC400, 450-8R
PC400, 450-8R 55
Failure code [CA274] PCV2 Open Error

User code Failure code PCV2 Open Error
Trouble
E10 CA274
Contents of
q Open error was detected in PCV2 circuit of supply pump.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Defective supply pump without turning starting switch ON.
1 PCV2
PCV2 (male) Resistance
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 Ω
ness
Wiring harness between ENG (female) (9) – Resis-
PCV2 (female) (1) tance
tor) Wiring harness between ENG (female) (10) Resis-
Possible causes Max. 1 Ω
– PCV2 (female) (2) tance
and standard
3 Min. 1 MΩ
cuit)
Min. 1 MΩ
– PCV2 (female) (2) and chassis ground tance
Between (9) – (10) 2.3 – 5.3 Ω
Min. 1 MΩ
ground
56 PC400, 450-8R
PC400, 450-8R 57
Failure code [CA322] Inj #1 Open/Short Error

User code Failure code Injector #1 open/short circuit error
Trouble
E11 CA322
Contents of
q Open or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of con-
troller
Problem that
q Combustion becomes irregular or engine hunts.
appears on
machine
Related infor-
mation

CN1 (male) Resistance
1 Defective No. 1 injector
Between (1) – (2) Max. 2 Ω
2 (Disconnection in wiring or – CN1 (female) (1) Max. 2 Ω
tance
tor) Max. 2 Ω
– CN1 (female) (2) tance
3
(Short circuit with GND cir- Wiring harness between CE01 (female) (45) Resis-
Max. 2 Ω
cuit) – CN1 (female) (1) and chassis ground tance
Possible causes
and standard
value in normal Between CE01 (female) (45) – each of
Short circuit in wiring har- Resis- Min.
state CE01 (female) pins (With all wiring harness
4 ness tance 100 kΩ
(with another wiring harness)
Between CE01 (female) (53) – each of
Resis- Min.
CE01 (female) pins (With all wiring harness
tance 100 kΩ
Connecting parts between No. 1 injector – engine wiring harness –

connector
Defective other cylinder If the failure codes of other injectors are displayed, carry out trou-
6
injectors or wiring harness ble shooting of them, too.

Between (45) – (53) Max. 2 Ω
58 PC400, 450-8R
Circuit diagram related to injector No. 1
PC400, 450-8R 59

Trouble
E11 CA323
Contents of
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

1 Defective No. 5 injector CN5 (male) Resistance

ness
Max. 2 Ω
3
cuit) Max. 2 Ω
– CN5 (female) (1) and chassis ground tance
Possible causes
value in normal without turning starting switch ON.
state Between CE01 (female) (46) – each of
Resis- Min.
tance 100 kΩ
connector
6

Between (46) – (60) Max. 2 Ω
60 PC400, 450-8R
PC400, 450-8R 61

Trouble
E11 CA324
Contents of
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation


ness
Max. 2 Ω
3
cuit) Max. 2 Ω
Possible causes
Resis- Min.
tance 100 kΩ
connector
6

Between (55) – (52) Max. 2 Ω
62 PC400, 450-8R
PC400, 450-8R 63

Trouble
E11 CA325
Contents of
q Open short circuit was detected in drive circuit of No. 6 injector.
trouble
Action of con-
troller
Problem that
appears on q Combustion becomes irregular or engine hunts.
machine
Related infor-
mation


2 (Disconnection in wiring or – CN6 (female) (1) Max. 2 Ω
tance
– CN6 (female) (2) Max. 2 Ω
tance
3
cuit) Max. 2 Ω
Possible causes
Resis- Min.
tance 100 kΩ
connector
6

Between (57) – (59) Max. 2 Ω
64 PC400, 450-8R
PC400, 450-8R 65

Trouble
E11 CA331
Contents of
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation


ness
Max. 2 Ω
3
cuit) Max. 2 Ω
Possible causes
state Short circuit in wiring har- Between CE01 (female) (54) – each of
Resis- Min.
4 ness CE01 (female) pins (With all wiring harness
tance 100 kΩ
(with another wiring harness) connectors disconnected)
Resis- Min.
tance 100 kΩ
connector
6

Between (54) – (51) Max. 2 Ω
66 PC400, 450-8R
PC400, 450-8R 67

Trouble
E11 CA332
Contents of
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation


ness
Max. 2 Ω
3
cuit) Max. 2 Ω
Possible causes
Resis- Min.
tance 100 kΩ
connector
6

Between (56) – (58) Max. 2 Ω
68 PC400, 450-8R
PC400, 450-8R 69
©2010 KOMATSU
All Rights Reserved
70
SEN04265-01
PC400, 450-8R
SEN04265-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
Failure code [CA342] Calibration Code Incompatibility............................................................................... 3

Failure code [CA351] Injectors Drive Circuit Error ...................................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................. 6
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................. 8
Failure code [CA441] Battery Voltage Low Error ........................................................................................ 10
Failure code [CA442] Battery Voltage High Error ....................................................................................... 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..................................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................................... 28
Failure code [CA757] All Persistent Data Lost Error ................................................................................... 30
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................. 32
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................................... 34
Failure code [CA2185] Throt Sens Sup Volt High Error.............................................................................. 36
PC400, 450-8R 1
Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................................... 37

Failure code [CA2249] Rail Press Very Low Error ...................................................................................... 38
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................................ 40
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................. 42
Failure code [D110KB] Battery Relay Drive S/C ......................................................................................... 44
Failure code [D196KA] Service Return Relay Disc. .................................................................................... 46
Failure code [D196KB] Service Return Relay S/C ...................................................................................... 48
Failure code [DA25KP] 5V sensor power supply output 1 abnormality....................................................... 50
Failure code [DA2SKQ] Model Selection Abnormality ................................................................................ 53
2 PC400, 450-8R
Failure code [CA342] Calibration Code Incompatibility
User code Failure code Calibration code incompatibility

Trouble
E10 CA342
Contents of
q Incompatibility of data occurred in engine controller.
trouble
Action of con-
troller
Problem that
appears on q Normal operation, engine stopped, or start disabled
machine
Related infor-
mation

Possible causes
and standard 1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
value in normal
state Engine controller may be defective. (Troubleshooting cannot be
carried out.)
PC400, 450-8R 3
Failure code [CA351] Injectors Drive Circuit Error
User code Failure code Injectors drive circuit error

Trouble
E10 CA351
Contents of
q There is error in drive power circuit of injector.
trouble
Action of con-
q Limits output and continues operation.
troller
q Exhaust gas becomes black.
Problem that
q Combustion becomes irregular.
appears on
machine
q Engine cannot be started.
Related infor-
mation
1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.

Defective relay for engine
3 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
Possible causes this time, replaced relay is defective.
and standard
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis- Max.
ness (female) (3) tance 0.5 
defective contact in connec- Wiring harness between R23, R24 (female) Resis- Max.
tor) (5) – CE03 (female) (3) tance 0.5 
Max. 10 
– chassis ground (T11) tance
If causes 1 – 4 are not detected, engine controller may be defec-
out.)
4 PC400, 450-8R
Circuit diagram related to engine controller power supply
PC400, 450-8R 5
Failure code [CA352] Sens Supply 1 Volt Low Error
User code Failure code Sensor power supply 1 voltage low error
Trouble
E15 CA352
Contents of
q Low voltage was detected in sensor power supply 1 circuit.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Disconnect sensor
and wiring harness at
Ambient pressure
right in order and PAMB
sensor
Defective sensor or wiring carry out operation to
1 reproduce trouble. If
harness
“E” of failure code
Possible causes goes off when sen-
and standard sor or wiring harness
Engine wiring har-
value in normal is disconnected, that CE01
ness
state sensor or wiring har-
ness is defective.
2
out.)
6 PC400, 450-8R
PC400, 450-8R 7
Failure code [CA386] Sens Supply 1 Volt High Error
User code Failure code Sensor power supply 1 voltage high error
Trouble
E15 CA386
Contents of
q High voltage was detected in sensor power supply 1 circuit.
trouble
Action of con-
troller
Problem that
appears on
machine
Related infor-
mation

Possible causes
and standard 1
value in normal
state
8 PC400, 450-8R
PC400, 450-8R 9
Failure code [CA441] Battery Voltage Low Error
User code Failure code Battery voltage low error

Trouble
E10 CA441
Contents of
q There is low voltage in controller power supply circuit.
trouble
Action of con-
troller
Problem that
q Engine stops.
appears on
machine
Related infor-
mation

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)

this time, replaced relay is defective.
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
Possible causes Max. 10 
ness (female) (3) tance
value in normal Wiring harness between R23, R24 (female) Resis-
defective contact in connec- Max. 10 
state (5) – CE03 (female) (3) tance
tor)
Max. 10 
ness Wiring harness between F01-19 – R23, R24 Resis- Min.
6
(Short circuit with GND cir- (female) (3) and chassis ground tance 100 k
cuit)
Wiring harness between R23, R24 (female) Resis-
Max. 10 
(5) – CE03 (female) (3) and chassis ground tance
Between CE03 (female) (3) – CE03 (female) Resis- Min.
Short circuit in wiring har- (1) pins (With battery terminal disconnected) tance 100 k
7 ness Between CE03 (female) (3) – each of CE02
Resis- Min.
(with another wiring harness) (female) pins (With battery terminal discon-
tance 100 k
nected)
Between CE03 (female) (1) – each of CE02
Resis- Min.
(female) pins (With battery terminal discon-
tance 100 k
nected)
10 PC400, 450-8R

Connecting parts between fuse No. 19 – machine wiring harness –
connector
Possible causes q Corrosion, bend, breakage, push-in, or expansion of pin
and standard q Moisture or dirt in connector or defective insulation
state and start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 (female) Starting switch Voltage

ON Min. 24 V
Between (3) – (1)
START Min. 12 V
PC400, 450-8R 11
Failure code [CA442] Battery Voltage High Error
User code Failure code Battery voltage high error

Trouble
E10 CA442
Contents of
q There is high voltage (36 V or higher) in controller power supply circuit.
trouble
Action of con-
troller
Problem that
appears on q 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
Medium or higher 27.5 – 29.5 V
ground
3 Defective engine controller CE03 (female) Voltage
Between (3) – (1) Max. 32 V
12 PC400, 450-8R
PC400, 450-8R 13
Failure code [CA449] Rail Press Very High Error
User code Failure code Common rail pressure very high error
Trouble
E11 CA449
Contents of
q There is high pressure error (2) in common rail circuit.
trouble
Action of con-
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
q If this error occurs during air bleeding after the fuel filter was re-
placed, air may remain in the fuel circuit. Keep running the en-
gine 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.
q Measured in fuel filter outlet side.
During high idle (if Max. 0.48 MPa {Max.
Pressure in fuel
engine can be
low-pressure circuit
started) 4.9 kg/cm2}
Possible causes
and standard a For check of pressure in fuel low pressure circuit, see Testing
value in normal and adjusting, Checking fuel pressure.
state q Measured in fuel filter inlet and outlet sides.
q 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 {Max.
3 During high idle
circuit parts low-pressure circuit 1.4 kg/cm2}
a For check of fuel suction pressure, see Testing and adjusting,
Checking fuel pressure.
q Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit
Max. 33.9 kPa {Max.
pressure (gear pump During high idle
254 mmHg}
side)
a For check of fuel return circuit pressure, see Testing and adjust-
ing, Checking fuel pressure.
Max. 27.1 kPa {Max.
pressure (fuel con- During high idle
203 mmHg}
nector side)
a Directly check for fuel leakage from fuel tube of fuel cooler,
4 Defective fuel cooler O-ring, seal washer damage, and check valve clogging or dam-
age.
14 PC400, 450-8R

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
sure stopped {0 ± 4 kg/cm2}
Defective supply pump actu-
Possible causes 7 a Prepare with starting switch OFF (INSITE connection), then
ator
and standard start engine and carry out troubleshooting.
value in normal q Measured after one minute or more lapsed at idle.
state 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
9
ground wiring harness CE03 (female) Resistance
Between (1) – chassis ground Max. 10 
10 Defective supply pump If causes 1 – 10 are not detected, supply pump may be defective.
PC400, 450-8R 15
Circuit diagram related to common rail pressure sensor and engine controller ground line
16 PC400, 450-8R
PC400, 450-8R 17
Failure code [CA451] Rail Press Sensor High Error

User code Failure code Common rail pressure sensor high error
Trouble
E11 CA451
Contents of
q There is high voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
troller
Problem that
q Engine speed or output lowers.
appears on
machine
Related infor-
mation

1
PFUEL (male) Voltage
Defective common rail pres-
sure sensor
and standard – PFUEL (female) (2) and chassis ground
value in normal
4 ness Wiring harnesses between CE01 (female)
(with another wiring harness) (25) – PFUEL (female) (2) and between Resis- Min.
tance 100 k
CE01 (female) (33) – PFUEL (female) (1)
Connecting parts between common rail pressure sensor – engine
5
18 PC400, 450-8R
Circuit diagram related to common rail pressure sensor
PC400, 450-8R 19
Failure code [CA452] Rail Press Sensor Low Error
User code Failure code Common rail pressure sensor low error
Trouble
E11 CA452
Contents of
q There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of con-
troller
Problem that
q Engine speed or output lowers.
appears on
machine
Related infor-
mation

1
PFUEL (male) 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 (Short circuit with GND cir- Wiring harness between CE01 (female) (25) Resis- Min.
and standard cuit) – PFUEL (female) (2) and chassis ground tance 100 k
(with another wiring harness) – PFUEL (female) (2) and between CE01 Resis- Min.
tance 100 k
(female) (47) – PFUEL (female) (3)
Connecting parts between common rail pressure sensor – engine
5
20 PC400, 450-8R
Circuit diagram related to common rail pressure sensor
PC400, 450-8R 21
Failure code [CA553] Rail Press High Error
User code Failure code Common rail pressure high error

Trouble
E15 CA553
Contents of
q There is high pressure error (1) in common rail circuit.
trouble
Action of con-
troller
Problem that
q Engine sound becomes large when no or light load is applied.
appears on
machine
Related infor-
mation
Possible causes Ground terminal may be connected defectively. Check following

and standard terminals directly.
value in normal Defective connection of q Ground terminal of machine ((–) terminal of battery)
2
state ground terminal q Ground terminal of engine
q Ground terminal of engine controller
q 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, 450-8R
Failure code [CA554] Rail Press Sensor In Range Error
User code Failure code Rail Press Sensor In Range Error

Trouble
E11 CA554
Contents of
q In range error occurred in common rail pressure sensor circuit.
trouble
Action of con-
q Limits output and continues operation (limits common rail pressure).
troller
Problem that
machine
Related infor-
mation

and standard
state
PC400, 450-8R 23
Failure code [CA559] Rail Press Low Error
User code Failure code Common rail pressure low error

Trouble
E15 CA559
Contents of
q There is low pressure error (1) in common rail circuit.
trouble
Action of con-
troller
Problem that q Engine does not start at all or does not start easily.
appears on q Exhaust gas becomes black.
machine q Engine output lowers.
Related infor-
mation

Fuel may be leaking to outside. Check it directly (Check visually
1 Fuel leakage to outside
while running engine at low idle).
q Measured in fuel filter inlet side.
q Cranking speed: Min. 150 rpm
Pressure in fuel Min. 0.14 MPa

During cranking
low-pressure circuit {Min. 1.4 kg/cm2}
q Measured in fuel filter outlet side.
Pressure in fuel Min. 0.48 MPa

During high idle
low-pressure circuit {Min. 4.9 kg/cm2}
Possible causes a For check of pressure in fuel low pressure circuit, see Testing
and standard and adjusting, Checking fuel pressure.
value in normal q Measured in fuel filter inlet and outlet sides.
state
Defect in low pressure circuit q Pressure drop in fuel low-pressure circuit = Fuel filter inlet pres-
2 sure — Fuel filter outlet pressure
parts
Pressure drop in fuel Max. 0.14 MPa
During high idle
low-pressure circuit {Max. 1.4 kg/cm2}
q Measured in gear pump fuel inlet side of supply pump.

Max. 33.9 kPa
pressure (gear pump During high idle
{Max. 254 mmHg}
side)
q Measured in fuel connector side.

Max. 27.1 kPa
pressure (fuel con- During high idle
{Max. 203 mmHg}
nector side)
24 PC400, 450-8R

a For check of return rate from injector, see Testing and adjusting,
Checking fuel return rate and leakage.
During cranking
Defective injector (if engine cannot be Max. 100 cc/30 sec.
3 (including high pressure pip- started)
ing in head) Return rate from
injector During low idle
(if engine can be Max. 300 cc/45 sec.
started)
a For check of return rate from supply pump, see Testing and ad-
justing, Checking fuel return rate and leakage.
During cranking
(if engine cannot be Max. 100 cc/30 sec.
4 Defective supply pump started)
Return rate from sup-
Possible causes ply pump During low idle
and standard (if engine can be Max. 300 cc/45 sec.
value in normal started)
state
a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During cranking Max. 30 cc/min
pressure limiter
Defective supply pump a Remove the supply pump head, and directly check that the
6
plunger plunger is not damaged.
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.
7 Air in low pressure circuit
q If this error occurs during air bleeding after the fuel filter was re-
placed, air may remain in the fuel circuit. Keep running the en-
gine 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.
PC400, 450-8R 25
Failure code [CA689] Eng Ne Speed Sensor Error
User code Failure code Engine Ne speed sensor error

Trouble
E15 CA689
Contents of
q There is error in signal from engine Ne speed sensor.
trouble
Action of con-
q Continues control with signal from engine Bkup speed sensor.
troller
Problem that q Engine hunts.
appears on q Engine does not start easily.
Related infor-
mation

Defective Ne speed sensor If failure code [CA238] is also indicated, carry out troubleshooting
1
NE (male) Voltage
Defective engine Ne speed
sensor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed
Possible causes clearance. Check it directly.
sensor
and standard
Breakage of rotation sensor
value in normal 4 Rotation sensor wheel may be broken. Check it directly.
wheel
state
tor) – NE (female) (3) tance
6
cuit) – NE (female) (3) and chassis ground tance 100 k
Wiring harness between CE01 (female) (27)
– NE (female) (3) and chassis ground
26 PC400, 450-8R

– NE (female) (3) and between CE01
8 ness tance 100 k
(female) (16) – NE (female) (1)
Resis- Min.
– NE (female) (3) and between CE01
Possible causes tance 100 k
(female) (48) – NE (female) (2)
and standard
value in normal Connecting parts between engine Ne speed sensor – engine wiring
state harness – engine controller may be defective. Check them directly.
connector

Circuit diagram related to engine Ne speed sensor
PC400, 450-8R 27
Failure code [CA731] Eng Bkup Speed Sens Phase Error
User code Failure code Engine Bkup speed sensor phase error
Trouble
E15 CA731
Contents of
q Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of con-
q Controls the engine with signal from engine Ne speed sensor.
troller
Problem that
q Running engine stops (When Ne speed sensor is also abnormal)
appears on
q Stopped engine cannot be started (When Ne speed sensor is also abnormal)
machine
Related infor-
mation

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. Check it directly.
speed sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor may be broken. Check it directly.
speed sensor
Rotation sensor wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or
1) Set No. 1 cylinder at compression top dead center (Match
3 breakage of rotation sensor
stamped mark).
wheel on crankshaft side
2) If center of oblong hole of rotation sensor wheel is at tip of Ne
speed sensor, rotation sensor wheel is installed normally.
Possible causes Rotation sensor ring on camshaft side may be installed defectively
and standard or broken. Check it according to the following procedure.
value in normal Defective installation or 1) Set No. 1 cylinder at compression top dead center (Match
state 4 breakage of rotation sensor stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 crest) of rotation sensor ring are seen through
sensor mounting hole, rotation sensor ring is installed normally.
Defective timing of crank- Timing of crankshaft and camshaft may be defective. Check it
5
shaft and camshaft directly.
Ground terminal may be connected defectively. Check following

terminals directly.
Defective connection of q Ground terminal of machine ((–) terminal of battery)
6
ground terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
28 PC400, 450-8R
PC400, 450-8R 29
Failure code [CA757] All Persistent Data Lost Error

User code Failure code All persistent data lost error
Trouble
E10 CA757
Contents of
q All data in engine controller are lost.
trouble
Action of con-
troller
Problem that
q Engine may stop and may not be started again.
appears on
q Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related infor-
mation
Looseness or corrosion of
2 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.
Battery (1 piece) Starting switch Voltage
3 Defective battery voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.

Possible causes this time, replaced relay is defective.
state
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resis-
ness Max. 10 
(female) (3) tance
Wiring harness between R23, R24 (female) Resis-
tor) (5) – CE03 (female) (3) tance
Max. 10 
Connecting parts between fuse No. 19 – machine wiring harness –
connector

and start engine and carry out troubleshooting in each case.
8 Defective engine controller CE03 (female) Starting switch Voltage

ON Min. 24 V
Between (3) – (1)
START Min. 12 V
30 PC400, 450-8R
PC400, 450-8R 31
Failure code [CA778] Eng Bkup Speed Sensor Error

User code Failure code Engine Bkup speed sensor error
Trouble
E15 CA778
Contents of
q There is error in signal from engine Bkup speed sensor.
trouble
Action of con-
q Continues control with signal from engine Ne speed sensor.
troller
Problem that
appears on
machine
Related infor-
mation

1
G (male) Voltage
Defective engine Bkup
speed sensor
Breakage or improper clear-
Engine Bkup speed sensor may be broken or may have improper
3 ance of engine Bkup speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor ring may be broken. Check it directly.
ring
Possible causes
and standard
state
tor) – G (female) (3) tance
6
cuit) – G (female) (3) and chassis ground tance 100 k
– G (female) (3) and chassis ground
Short circuit in wiring har- Wiring harness between CE01 (female) (26)
Resis- Min.
8 ness – G (female) (3) and between CE01
tance 100 k
(with another wiring harness) (female) (37) – G (female) (1)
Resis- Min.
– G (female) (3) and between CE01
tance 100 k
(female) (47) – G (female) (2)
32 PC400, 450-8R

Connecting parts between engine Bkup speed sensor – engine wir-
Possible causes 9
and standard q Corrosion, bend, breakage, push-in, or expansion of pin
value in normal q Moisture or dirt in connector or defective insulation
Circuit diagram related to engine Bkup speed sensor
PC400, 450-8R 33
Failure code [CA1633] KOMNET Datalink Timeout Error

User code Failure code KOMNET Datalink timeout error
Trouble
E0E CA1633
Contents of q Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of con- q Continues operation in default mode.
Problem that
q Information may not transmitted normally by KOMNET communication and machine may not op-
appears on
erate normally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8), Resis-
ness (Disconnection in wir- (9) – CP01 (female) (45), – CE02 (female) Max. 1 
1 tance
ing or defective contact in (46), – K02 (female) (A)
connector) Wiring harness between CM02 (female) (10)
Resis-
– CP01 (female) (64), – CE02 (female) (47), Max. 1 
tance
– K02 (female) (B)
Wiring harness between CM02 (female) (8),
Ground fault in wiring har- Resis-
(9) – CP01 (female) (45), – CE02 (female) Min. 1 M
2 ness (Short circuit with GND (46), – K02 (female) (A), – N08 (male) (3) tance
circuit)
Possible causes Wiring harness between CM02 (female) (10)
Resis-
and standard – CP01 (female) (64), – CE02 (female) (47), Min. 1 M
tance
value in normal – K02 (female) (B), – N08 (male) (10)
Hot short (Short circuit with (9) – CP01 (female) (45), – CE02 (female) Voltage Max. 1 V
3
24V circuit) in wiring harness (46), – K02 (female) (A), – N08 (male) (3)
– CP01 (female) (64), – CE02 (female) (47), Voltage Max. 1 V
– K02 (female) (B), – N08 (male) (10)
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal short cir- K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 
If causes 1 – 4 are not detected, engine controller may be defec-
5 Defective pump controller tive.
34 PC400, 450-8R
Circuit diagram related to KOMNET communication
PC400, 450-8R 35
SEN04265-01 4 0 T r o u b l e s h o o t i n g
Failure code [CA2185] Throt Sens Sup Volt High Error

User code Failure code Throttle sensor supply voltage high error
Trouble
E14 CA2185
Contents of
q High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related infor-
mation

Short circuit in wiring har- Between CE02 (female) (22) – each of
Resis- Min.
1 ness CE02 (female) pins (With P20 discon-
tance 100 k
(with another wiring harness) nected)
Possible causes
and standard Between CE02 (female) (22) – CE03 Resis- Min.
value in normal (female) (3) (With P20 disconnected) tance 100 k
state Connecting parts between fuel control dial – machine wiring har-
connector
3 Defective engine controller tive.
36 PC400, 450-8R
Failure code [CA2186] Throt Sens Sup Volt Low Error

User code Failure code Throttle sensor supply voltage low error
Trouble
E14 CA2186
Contents of
q Low voltage was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related infor-
mation
1
cuit) – P20 (female) (1) and chassis ground tance 100 k
Possible causes
2 ness
and standard
(with another wiring harness) Between CE02 (female) (9) – each of CE02 Resis- Min.
value in normal (female) pins (With P20 disconnected) tance 100 k
state
connector
4 Defective engine controller tive.
PC400, 450-8R 37
Failure code [CA2249] Rail Press Very Low Error

User code Failure code Common rail pressure very low error
Trouble
E11 CA2249
Contents of
q There is low pressure error (2) in common rail circuit.
trouble
Action of con-
troller
Problem that q Engine does not start easily.
appears on q Exhaust gas becomes black.
Related infor-
mation

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
38 PC400, 450-8R
PC400, 450-8R 39
Failure code [CA2555] Grid Htr Relay Volt High Error

User code Failure code Grid heater relay volt high error
Trouble
E15 CA2555
Contents of
q Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at
appears on
low temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) Resistance
Defective automatic pre- Between (1) – (2) 300 – 600 
1 heater relay a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection). and carry out troubleshooting. (Troubleshooting by replace-
ment)
Replace automatic preheater relay (R18) with another relay and
perform reproducing operation. If “E” of failure code goes off at this
time, replaced relay is defective.
Possible causes
2 (Disconnection in wiring or – R18 (female) (1) Max. 10 
and standard tance
state
tor) Max. 10 
– R18 (female) (2) tance
3 ness Between CE02 (female) (40) – each of
Resis- Min.
(with another wiring harness) CE02 (female) pins (With R18 discon-
tance 100 k
nected)
Connecting parts between automatic preheater relay – machine
4
Between (40) – (42) 300 – 600 
40 PC400, 450-8R
Circuit diagram related to preheating, starting and charging engine
PC400, 450-8R 41
Failure code [CA2556] Grid Htr Relay Volt Low Error

User code Failure code Grid heater relay volt low error
Trouble
E15 CA2556
Contents of
q Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of con-
troller
Problem that
q Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at
appears on
low temperature).
machine
Related infor- q Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
mation below –4°C.

without turning starting switch ON. (Troubleshooting for relay
unit)
R18 (male) Resistance
Defective automatic pre- Between (1) – (2) 300 – 600 
1 heater relay a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection). and carry out troubleshooting. (Troubleshooting by replace-
ment)
Replace automatic preheater relay (R18) with another relay and
perform reproducing operation. If “E” of failure code goes off at this
time, replaced relay is defective.
Possible causes ness without turning starting switch ON.
2
and standard (Short circuit with GND cir- Wiring harness between CE02 (female) (40) Resis- Min.
value in normal cuit) – R18 (female) (1) and chassis ground tance 100 k
3 ness Between CE02 (female) (40) – each of
Resis- Min.
(with another wiring harness) CE02 (female) pins (With R18 discon-
tance 100 k
nected)
Connecting parts between automatic preheater relay – machine
4
Between (40) – (42) 300 – 600 
42 PC400, 450-8R
Circuit diagram related to preheating, starting and charging engine
PC400, 450-8R 43
Failure code [D110KB] Battery Relay Drive S/C

User code Failure code Battery relay drive short
Trouble
— D110KB
Contents of
q Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of con- q Turns output to battery relay drive circuit OFF.
Problem that
appears on q Engine does not stop.
machine
Related infor- q Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
mation (Code 03700: Controller Output)

Battery relay Resistance
Defective battery relay
1 Between R02 (terminal BR) –
(Internal defect) There is continuity
R01 (terminal E)
Between R02 (terminal BR) –
Min. 1 M
Possible causes chassis ground
ness
state 2 Wiring harness between CP03 (female) (4)
– D01 – J01 – R02 (terminal BR) and chas- Min. 1 M
cuit) tance
sis ground
Turn starting switch
3 Defective pump controller CP03 (female) Voltage
OFF.
Between (4) – chas- 20 – 30 V
ON o OFF
sis ground (4 – 7 sec.)
44 PC400, 450-8R
Circuit diagram related to battery relay drive
PC400, 450-8R 45
Failure code [D196KA] Service Return Relay Disc.

User code Failure code Service return relay disconnection
Trouble
— D196KA
Contents of q When service return relay circuit was disconnected with GND (when output was turned OFF), 24V
trouble was not generated.
Action of con- q None in particular.
Problem that
appears on q Hydraulic circuit for attachment does not change to single operation circuit.
machine
q Carry out troubleshooting only for setting with ATT. (Confirm settings on monitor panel.)
a This code detects only a trouble in the primary side (coil side) of service return relay.
Related infor- When service return solenoid may be in defective operation, check the power supply, wiring
mation harness, and solenoid in the secondary side (Limit SW side) of the relay.
q 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 broken, circuit probably has ground fault.

Defective service return
2
relay (Internal disconnection) R20 (male) Resistance
Between (1) – (2) 100 – 500 
and standard without turning starting switch ON.
value in normal ness Wiring harness between CP02 (female) (8) Resis-
3 Min. 1 M
state (Short circuit with GND cir- – R20 (female) (2) and chassis ground tance
cuit) Wiring harness between R20 (female) (1) – Resis-
Min. 1 M
J03 – F01-2 outlet and chassis ground tance
CP02 Working mode Voltage
4 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – chas- selected
sis ground When B-mode is
Max. 1 V
selected
46 PC400, 450-8R
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-8R 47
Failure code [D196KB] Service Return Relay S/C

User code Failure code Service return relay short
Trouble
— D196KB
Contents of q When service return relay circuit was connected to GND (when output was turned ON), abnormal
trouble current flowed.
Action of con- q Turns output to service return relay circuit OFF.
Problem that
machine
q Carry out troubleshooting only for setting with ATT. (Confirm settings on monitor panel.)
a This code detects only a trouble in the primary side (coil side) of service return relay.
Related infor- When service return solenoid may be in defective operation, check the power source, wiring
mation harness, and solenoid in the secondary side (Limit SW side) of the relay.
q Operating condition of service return relay (ON/OFF) can be checked with monitoring function.

1
24V circuit) in wiring harness Wiring harness between CP02 (female) (8)
Voltage Max. 1 V
Possible causes – R20 (female) (2) and chassis ground
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state
2 Defective pump controller When B-mode is not
20 – 30 V
Between (8) – chas- selected
sis ground When B-mode is
Max. 1 V
selected
48 PC400, 450-8R
Circuit diagram related to service return relay and solenoid of pump controller
PC400, 450-8R 49
Failure code [DA25KP] 5V sensor power supply output 1 abnormality

User code Failure code 5V sensor power supply output 1 abnormality
Trouble
— DA25KP
Contents of
q Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of con- q Turns output of 5V sensor power supply output 1 OFF.
Problem that q Automatic gear shifting function does not work (pump pressure sensor system).
appears on q Auto-decelerator keeps working and is not reset or fine control performance of work equipment is
machine lowered (PPC pressure sensor system).
Related infor-
q Method of reproducing failure code; Turn starting switch ON.
mation

Bucket DUMP PPC
P01
pressure switch
Boom RAISE PPC
P03
pressure switch
Disconnect sensors at right in Bucket CURL PPC
P04
Defective pressure sensor order and carry out operation to pressure switch
1
(Internal short circuit) reproduce trouble. If "E" of fail- Arm IN PPC pres-
ure code goes off when a sensor P05
sure switch
is disconnected, that sensor is
defective. Swing RIGHT PPC
P07
pressure switch
Swing LEFT PPC
P08
pressure switch
Pump pressure sen-
P25
sor
Possible causes
state Wiring harness between CP01 (female) (34)
– P01 (female) (2), P01 (female) (1) – J03 –
Resis-
ground (T08) Min. 1 M
tance
[Bucket DUMP PPC pressure switch sys-
tem]
Wiring harness between CP01 (female) (53)
– P03 (female) (2), P03 (female) (1) – J03 – Resis-
Min. 1 M
Ground fault in wiring har- ground (T08) tance
ness [Boom RAISE PPC pressure switch system]
2 Wiring harness between CP01 (female) (73)
(Short circuit with GND cir-
cuit) – P04 (female) (2), P04 (female) (1) – J03 – Resis-
Min. 1 M
ground (T08) tance
[Bucket CURL PPC pressure switch system]
Min. 1 M
ground (T08) tance
[Arm IN PPC pressure switch system]
Min. 1 M
ground (T08) tance
[Swig RIGHT PPC pressure switch system]
50 PC400, 450-8R

Ground fault in wiring har- Min. 1 M
ground (T08) tance
ness [Swing LEFT PPC pressure switch system]
2
cuit) Resis-
– J07 – P25 female (3) Min. 1 M
tance
[Pump pressure sensor system]
ground (T08) Voltage Max. 1 V
[Bucket CURL PPC pressure sensor sys-
tem]
Voltage Max. 1 V
ground (T08)
[Swing LEFT PPC pressure sensor system]
Possible causes
and standard Voltage Max. 1 V
ground (T08)
value in normal
[Arm IN PPC pressure sensor system]
state Hot short (Short circuit with Wiring harness between CP01 (female) (17)
3 24 V circuit) in wiring har- – P05 (female) (2), P05 (female) (1) – J03 –
ness ground (T08) Voltage Max. 1 V
[Bucket DUMP PPC pressure sensor sys-
tem]
[Boom RAISE PPC pressure sensor sys-
tem]
[Swing RIGHT PPC pressure sensor sys-
tem]
– J07 – P25 (female) (3) [Pump pressure Voltage Max. 1 V
sensor system]
If causes 1 – 3 are not detected, pump controller may be defective.

4 Defective pump controller
PC400, 450-8R 51
Circuit diagram related to pressure sensor power supply of pump controller
52 PC400, 450-8R
Failure code [DA2SKQ] Model Selection Abnormality

User code Failure code Model selection abnormality
Trouble
— DA2SKQ
Contents of
q Model code signal for model which is not registered in controller is input.
trouble
Action of con- q Changes input model code to code of default model (PC300) and continues control.
Problem that
appears on q None in particular.
machine
q Controller-recognized model name (digits) can be checked with monitoring function. (Code: 00200)
Related infor-
q Input of model selection signal (ON/OFF) can be checked with monitoring function.
mation
(Code 02200: Switch Input 2)

Defective model selection without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or
Between (1), (2), (3), (7) – (8) Max. 1 
short circuit)
Between (5), (6) – (8) Min. 1 M
Wiring harness between CP01 (female) (58) Resis-
Max. 1 
– S30 (male) (4) and chassis ground tance
Max. 1 
Disconnection in wiring har- – S30 (male) (3) tance
ness Wiring harness between CP01 (female) (21) Resis-
2 (Disconnection in wiring or Max. 1 
– S30 (male) (2) tance
tor) Max. 1 
– S30 (male) (1) tance
Possible causes
and standard Wiring harness between CP01 (female) (39) Resis-
Max. 1 
value in normal – S30 (male) (7) tance
state Wiring harness between S30 (male) (8) – Resis-
Max. 1 
J05 – chassis ground tance
Ground fault in wiring har- Min. 1 M
ness
3
(Short circuit with GND cir- Wiring harness between CP01 (female) (39) Resis-
Min. 1 M
cuit) – S30 (male) (7) and chassis ground tance
Min. 1 M
CP01 Voltage
4 Defective pump controller Between (21), (39), (44), (58) –
20 – 30 V
chassis ground
Between (21), (39) (77) – chas-
Max. 1 V
sis ground
PC400, 450-8R 53
Circuit diagram related to model selection connector of pump controller
54 PC400, 450-8R
PC400, 450-8R 55
©2009 KOMATSU
All Rights Reserved
56
SEN04266-02
PC400, 450-8R
SEN04266-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
Failure code [DA2RMC] CAN discon (Pump con detected)........................................................................ 4

Failure code [DAFRMC] CAN discon (Monitor detected)............................................................................ 6
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................................... 8
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................................... 10
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality .......................................................................... 12
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality........................................................ 14
Failure code [DW43KA] Travel Speed Sol. Disc. ........................................................................................ 16
Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................................... 18
Failure code [DW45KA] Swing Brake Sol. Disc. ......................................................................................... 20
Failure code [DW45KB] Swing Brake Sol. S/C ........................................................................................... 24
Failure code [DW91KA] Travel Junction Sol. Disc. ..................................................................................... 26
Failure code [DW91KB] Travel Junction Sol. S/C ....................................................................................... 28
Failure code [DWA2KA] Attachment Sol Open Circuit................................................................................ 30
Failure code [DWJ0KA] Merge-divider Sol. Disc ........................................................................................ 31
Failure code [DWJ0KB] Merge-divider Sol. S/C ......................................................................................... 33
Failure code [DWK0KA] 2-stage Relief Sol. Disc........................................................................................ 35
Failure code [DWK0KB] 2-stage Relief Sol. S/C......................................................................................... 37
Failure code [DXA0KA] PC-EPC Sol. Disc. ................................................................................................ 39
PC400, 450-8R 1
Failure code [DXA0KB] PC-EPC Sol. S/C .................................................................................................. 41

Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................................. 43
Failure code [DXE0KB] LS-EPC Sol. S/C ................................................................................................... 45
Failure code [DXE4KA] Service Current EPC Disc..................................................................................... 47
Failure code [DXE4KB] Service Current EPC S/C...................................................................................... 48
Failure code [DY20KA] Wiper Working Abnormality ................................................................................... 49
Failure code [DY20MA] Wiper Parking Abnormality ................................................................................... 51
Failure code [DY2CKB] Washer Drive Short............................................................................................... 53
Failure code [DY2DKB] Wiper Drive (For) Short......................................................................................... 55
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................................ 57
2 PC400, 450-8R
PC400, 450-8R 3
Failure code [DA2RMC] CAN discon (Pump con detected)

User code Failure code CAN disconnection (Pump controller detected)
Trouble
E0E DA2RMC
Contents of q Pump controller detected communication error in CAN communication circuit between machine
trouble monitor and engine controller.
Action of con- q Continues operation with information of CAN communication just before detection of error.
Problem that
q Information may not transmitted normally by CAN communication and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed section.)
machine
Related infor-
mation

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (Disconnection in wir- (9) – CP01 (female) (45), – CE02 (female) Max. 1 Ω
1 tance
ing or defective contact in (46), – K02 (female) (A)
connector) Wiring harness between CM02 (female) (10)
Resis-
– CP01 (female) (64), – CE02 (female) (47), Max. 1 Ω
tance
Ground fault in wiring har- Resis-
(9) – CP01 (female) (45), – CE02 (female) Min. 1 MΩ
2 ness (Short circuit with GND tance
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female) (10)
and standard Resis-
– CP01 (female) (64), – CE02 (female) (47), Min. 1 MΩ
value in normal tance
– K02 (female) (B), – N08 (male) (10)
state
Max. 5.5
Hot short (Short circuit with (9) – CP01 (female) (45), – CE02 (female) Voltage
3 V
24V circuit) in wiring harness (46), – K02 (female) (A), – N08 (male) (3)
Max. 5.5
– CP01 (female) (64), – CE02 (female) (47), Voltage
V
– K02 (female) (B), – N08 (male) (10)
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 Ω
If causes 1 – 4 are not detected, pump controller may be defective.
4 PC400, 450-8R
Circuit diagram related to CAN communication of machine monitor
PC400, 450-8R 5
Failure code [DAFRMC] CAN discon (Monitor detected)

Action code Failure code CAN disconnection (Monitor detected)
Trouble
E0E DAFRMC
Contents of q Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of con-
q If cause of failuredisappears, system resets itself.
troller
Problem that q Information may not transmitted normally by CAN communication and machine may not operate
appears on normally.
machine (Trouble phenomenon depends on failed section.)
Related infor-
q Method of reproducingfailure code: Turn starting switch ON.
mation

Disconnection in wiring har-
ness Resis-
(9) – CP01 (female) (45), – CE02 (female) Max. 1 Ω
1 (Disconnection in wiring or tance
(46), – K02 (female) (A)
defective contactin connec-
tor) Wiring harness between CM02 (female) (10)
Resis-
– CP01 (female) (64), – CE02 (female) (47), Max. 1 Ω
tance
Ground faultin wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (9) – CP01 (female) (45), – CE02 (female) Min. 1 MΩ
2 tance
(Short circuit with GND cir- (46), – K02 (female) (A), – N08 (male) (3)
cuit) Wiring harness between CM02 (female) (10)
Possiblecauses Resis-
and standard – CP01 (female) (64), – CE02 (female) (47), Min. 1 MΩ
tance
value in normal – K02 (female) (B), – N08 (male) (10)
Hot short (Short circuit with Max. 5.5
(9) – CP01 (female) (45), – CE02 (female) Voltage
3 24 V circuit) in wiring har- V
(46), – K02 (female) (A), – N08 (male) (3)
ness
Max. 5.5
– CP01 (female) (64), – CE02 (female) (47), Voltage
V
– K02 (female) (B), – N08 (male) (10)
Defective CAN terminal
resistance
4
(Internal short circuit or dis- K02 (male) Resistance
connection)
Between (A) – (B) 120 ± 12 Ω
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective pump controller tive.
6 PC400, 450-8R
Circuit diagram related to CAN communication of machine monitor
PC400, 450-8R 7
Failure code [DHPAMA] F Pump Press Sensor Abnormality

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

Defective sensor power sup- If failure code [DA25KP] is also displayed, carry out troubleshoot-
1
ply system ing for it first.
Defective F pump pressure
2 sensor P25 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
Disconnection in wiring har- Wiring harness between CP01 (female) (9) Resis-
ness Max. 1 Ω
Possible causes tor) – P25 (female) (1) tance
value in normal Max. 1 Ω
state
4
cuit) Min. 1 MΩ
– P25 (female) (2) and chassis ground tance
Hot short (Short circuit with Wiring harness between CP01 (female) (9)
5 Voltage Max. 1 V
24V circuit) in wiring harness – P25 (female) (3) and chassis ground
Voltage Max. 1 V
– P25 (female) (2) and chassis ground
Hot short (Short circuit with
6
5V circuit) in wiring harness Wiring harness between CP01 (female) (9) Resis-
– P25 (female) (3) and CP01 (female) (49) – Min. 1 MΩ
tance
P25 (female) (2)
8 PC400, 450-8R

Possible causes
and standard
value in normal 7 Defective pump controller CP01 Voltage
state
Between (9) – (18) 4.5 – 5.5 V
Between (49) – (18) 0.5 – 4.5 V
Circuit diagram related to F pump pressure sensor of pump controller
PC400, 450-8R 9
Failure code [DHPBMA] R Pump Press Sensor Abnormality

User code Failure code R pump pressure sensor abnormality
Trouble
— DHPBMA
Contents of
q Signal voltage from R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- q Fixes R pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation q 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 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 Ω
tor) – P26 (female) (1) tance
Possible causes
and standard Max. 1 Ω
value in normal
state Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
4
cuit) Min. 1 MΩ
5 Voltage Max. 1 V
Voltage Max. 1 V
6 Defective pump controller CP01 Voltage

Between (9) – (18) 4.5 – 5.5 V
Between (68) – (18) 0.5 – 4.5 V
10 PC400, 450-8R
Circuit diagram related to R pump pressure sensor of pump controller
PC400, 450-8R 11
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality

User code Failure code Arm IN PPC pressure sensor abnormality
Trouble
— DHS3MA
Contents of
q Signal voltage from arm IN PPC pressure sensor is below 0.3 V or above 4.72 V.
trouble
Action of con- q Fixes arm IN PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation q Input from arm IN PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07200: Arm IN PPC pressure)

1
Defective arm IN PPC pres- P04 Voltage
2
sure sensor (Internal defect)
Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 Ω
Possible causes
value in normal
4
(Short circuit with GND cir- Wiring harness between P04 (female) (17) – Resis-
cuit) Min. 1 MΩ
P01 (female) (2) and chassis ground tance
5 Voltage Max. 1 V
Voltage Max. 1 V

Between (9) – (18) 4.5 – 5.5 V
Between (17) – (18) 0.5 – 4.5 V
12 PC400, 450-8R
Circuit diagram related to arm IN PPC pressure sensor of pump controller
PC400, 450-8R 13
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality

User code Failure code Bucket CURL PPC press sensor abnormality
Trouble
— DHS4MA
Contents of
q Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of con- q Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
mation q Input from bucket curl PPC 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 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 Ω
Possible causes
value in normal
4
cuit) Min. 1 MΩ
5 Voltage Max. 1 V
Voltage Max. 1 V

Between (9) – (18) 4.5 – 5.5 V
Between (73) – (18) 0.5 – 4.5 V
14 PC400, 450-8R
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
PC400, 450-8R 15
Failure code [DW43KA] Travel Speed Sol. Disc.

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

Defective travel speed sole-
1
noid (Internal disconnection) V04 (male) Resistance
Between (1) – (2) 20 – 60 Ω
ness
Possible causes 2 (Disconnection in wiring or Max. 1 Ω
– V04 (female) (2) tance
value in normal tor) Wiring harness between V04 (female) (1) – Resis-
Max. 1 Ω
state chassis ground tance
3
Voltage Max. 1 V
– V04 (female) (2) and chassis ground
CP02 (female) Resistance
Between (87) – chassis ground 20 – 60 Ω
16 PC400, 450-8R
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-8R 17
Failure code [DW43KB] Travel Speed Sol. S/C

User code Failure code Travel speed solenoid short
Trouble
— DW43KB
Contents of
q Abnormal current flowed at output to travel speed solenoid circuit.
trouble
Action of con- q Turns output to travel speed solenoid circuit OFF.
Problem that
appears on q Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
Related infor- q Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
mation (Code 02300: Solenoid 1)

Defective travel speed sole-
1 noid (Internal short circuit or V04 (male) Resistance
ground fault) Between (1) – (2) 20 – 60 Ω
Between (2) – chassis ground Min. 1 MΩ
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 CP02 (female) (87) Resis-
Min. 1 MΩ
– V04 (female) (2) and chassis ground tance
3 Defective pump controller CP02 Travel speed Voltage
Between (87) – chas- Lo Max. 1 V

sis ground Hi + Travel operation 20 – 30 V
18 PC400, 450-8R
Circuit diagram related to travel speed solenoid of pump controller
PC400, 450-8R 19
Failure code [DW45KA] Swing Brake Sol. Disc.

User code Failure code Swing holding brake solenoid disconnection
Trouble
E03 DW45KA
Contents of
q No current flows at output to swing holding brake solenoid circuit.
trouble
Problem that
appears on q Machine cannot swing.
machine
q Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring
function. (Code 02300: Solenoid 1)
q If solenoid and wiring harness are normal, operator can swing machine by setting emergency
swing brake release switch in release position (Swing holding brake does not work, however, when
Related infor-
machine stops).
mation
q Turn both of swing lock and emergency swing release switches OFF during troubleshooting.

Defective swing holding without turning starting switch ON.
1 brake solenoid (Internal dis-
V05 (male) Resistance
connection)
Between (1) – (2) 20 – 60 Ω
Defective swing lock switch S04 (female) Switch Resistance
2
OFF Max. 1 Ω
Between (3) – (4)
LOCK Min. 1 MΩ
and standard
Defective assembled-type without turning starting switch ON.
value in normal
3 diode D01
state D01 (male) Digital circuit tester Continuity
Between (7) – (3) Diode mode There is continuity
Wiring harness between CP02 (female) Resis-
Max. 1 Ω
Disconnection in wiring har- (101) – D01 (female) (7) tance
ness
Wiring harness between D01 (female) (3) – Resis-
J02 – S04 (male) (3) tance
tor) Wiring harness between S04 (male) (4) – Resis-
Max. 1 Ω
V05 (female) (2) tance
Wiring harness between V05 (female) (1) – Resis-
Max. 1 Ω
CP02 (female) (115), (117), (120) tance
20 PC400, 450-8R

Wiring harness between CP02 (female)
5 (101) – D01 – H15 – S04 (male) (3) and Voltage Max. 1 V
24V circuit) in wiring harness
Possible causes chassis ground
and standard Wiring harness between V05 (female) (2) –
Voltage Max. 1 V
value in normal H15 – S04 (male) (4) and chassis ground
state
CP02 (female) Disconnect D01 and Resistance
connect pins (3) and
Between (101) – (7) on female side 20 – 60 Ω
chassis ground directly.
PC400, 450-8R 21
Circuit diagram related to swing holding brake solenoid of pump controller
22 PC400, 450-8R
PC400, 450-8R 23
Failure code [DW45KB] Swing Brake Sol. S/C

User code Failure code Swing holding brake solenoid short
Trouble
E03 DW45KB
Contents of
q Abnormal current flowed at output to swing holding brake solenoid circuit.
trouble
Action of con- q Turns output to swing holding brake solenoid circuit OFF.
Problem that
appears on q Machine cannot swing.
machine
q Operating condition of swing holding brake solenoid (ON/OFF) can be checked with monitoring
function. (Code 02300: Solenoid 1)
Related infor-
q If solenoid and wiring harness are normal, operator can swing machine by setting emergency
mation
swing brake release switch in release position (Swing holding brake does not work, however, when
machine stops).

Defective swing holding
1 brake solenoid (Internal V05 (male) Resistance
short circuit or ground fault) Between (1) – (2) 20 – 60 Ω
Defective assembled-type without turning starting switch ON.
2 diode D01
D01 (male) Resistance
(Internal short circuit)
Possible causes Between (3) – (7) Min. 1 MΩ
and standard
Wiring harness between CP02 (female)
ness Resis-
3 (101) – D01 – J02 – H15 – S04 (male) (3) Min. 1 MΩ
(Short circuit with GND cir- tance
and chassis ground
cuit)
Min. 1 MΩ
H15 – S04 (male) (4) and chassis ground tance
4 Defective pump controller CP02 Swing lever Voltage
Between (101) – At neutral Max. 1 V

chassis ground At swing 20 – 30 V
24 PC400, 450-8R
Circuit diagram related to swing holding brake solenoid of pump controller
PC400, 450-8R 25
Failure code [DW91KA] Travel Junction Sol. Disc.

User code Failure code Travel junction solenoid disconnection
Trouble
— DW91KA
Contents of
q No current flows at output to travel junction solenoid circuit.
trouble
Problem that
appears on q Hard to turn when operating travel steering.
machine
q Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation

Defective travel junction without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 Ω
ness Wiring harness between CP02 (female) Resis-
Max. 1 Ω
2 (Disconnection in wiring or (110) – V02 (female) (2) tance
Possible causes defective contact in connec-
and standard Wiring harness between V02 (female) (1) –
tor) Resis-
value in normal CP02 (female) (115), (117), (120) and chas- Max. 1 Ω
tance
state sis ground
3
24V circuit) in wiring harness Wiring harness between CP02 (female)
Voltage Max. 1 V
(110) – V02 (female) (2) and chassis ground
4 Defective pump controller CP02 (female) Resistance
Between (110) – (115), (117),
20 – 60 Ω
(120)
26 PC400, 450-8R
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-8R 27
Failure code [DW91KB] Travel Junction Sol. S/C

User code Failure code Travel junction solenoid short
Trouble
— DW91KB
Contents of
q Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of con- q Turns output to travel junction solenoid OFF.
Problem that
appears on q Hard to turn when operating travel steering.
machine
Related infor- q Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.

Defective travel junction without turning starting switch ON.
solenoid V02 (male) Resistance
1
(Internal short circuit or
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP02 (female) Resis-
cuit) Min. 1 MΩ
(110) – V02 (female) (2) and chassis ground tance
3 Defective pump controller CP02 Travel lever Voltage
Between (110) – At straight-travel Max. 1 V

(115), (117), (120) At steering 20 – 30 V
28 PC400, 450-8R
Circuit diagram related to travel junction solenoid of pump controller
PC400, 450-8R 29
Failure code [DWA2KA] Attachment Sol Open Circuit

User code Failure code Attachment solenoid disconnection
Trouble
— DWA2KA
Contents of
q When output to service solenoid is turned OFF, disconnection was detected in circuit.
trouble
Problem that
machine
q Operating condition of service solenoid can be checked with monitoring function.
Related infor- (Code 02301: Solenoid 2)
mation q Method of reproducing failure code: Turn starting switch ON + Set machine in mode other than
breaker mode (B).

Defective service solenoid without turning starting switch ON.
1
Possible causes Between (1) - (2) 20 - 60 Ω
and standard
state Disconnection in wiring har- without turning starting switch ON.
ness
- V07 (female) (2) tance
tor) Wiring harness between CP02 (female) Resis-
Max. 1 Ω
(120) - V07 (female) (1) tance
Between (86) - chassis ground 20 - 60 Ω
Circuit diagram related to service solenoid
30 PC400, 450-8R
Failure code [DWJ0KA] Merge-divider Sol. Disc

User code Failure code Merge-divider solenoid disconnection
Trouble
— DWJ0KA
Contents of
q No current flows at output to merge-divider solenoid circuit.
trouble
Problem that
appears on q Single operation speed of work equipment and swing is high in lifting mode (L).
machine
q Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation
for failure code [DWJ0KB].)

Defective merge-divider without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 Ω
ness Wiring harness between CP02 (female) Resis-
Max. 1 Ω
Possible causes 2 (Disconnection in wiring or (112) – V03 (female) (2) tance
Wiring harness between V03 (female) (1) –
tor) Resis-
value in normal CP02 (female) (115), (117), (120) and chas- Max. 1 Ω
tance
state sis ground
3
Voltage Max. 1 V
Between (112) – (115), (117),
20 – 60 Ω
(120)
PC400, 450-8R 31
Circuit diagram related to merge-divider solenoid of pump controller
32 PC400, 450-8R
Failure code [DWJ0KB] Merge-divider Sol. S/C

User code Failure code Merge-divider solenoid short
Trouble
— DWJ0KB
Contents of
q Abnormal current flowed at output to merge-divider solenoid circuit.
trouble
Action of con- q Turns output to merge-divider solenoid circuit OFF.
Problem that
appears on q Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related infor- q Operating condition of merge-divider solenoid (ON/OFF) can be checked with monitoring function.

Defective merge-divider without turning starting switch ON.
1
value in normal 2
(Short circuit with GND cir- Wiring harness between CP02 (female) Resis-
state cuit) Min. 1 MΩ
(112) – V03 (female) (2) and chassis ground tance
CP02 Travel lever Voltage
At neutral Max. 1 V
Between (112) –
(115), (117), (120) When either side is
20 – 30 V
operated
PC400, 450-8R 33
Circuit diagram related to merge-divider solenoid of pump controller
34 PC400, 450-8R
Failure code [DWK0KA] 2-stage Relief Sol. Disc.

User code Failure code 2-stage relief solenoid disconnection
Trouble
— DWK0KA
Contents of
q No current flows at output to 2-stage relief solenoid circuit.
trouble
Problem that
appears on q Power maximizing function does not work.
machine
q Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.
Related infor-
mation
for failure code [DWK0KB].)

Defective 2-stage relief sole- without turning starting switch ON.
1 noid
Between (1) – (2) 20 – 60 Ω
ness
Possible causes 2 (Disconnection in wiring or Max. 1 Ω
(109) – V08 (female) (2) tance
value in normal tor) Wiring harness between V08 (female) (1) – Resis-
Max. 1 Ω
state CP02 (female) (115), (117), (120) tance
3
Voltage Max. 1 V
Between (109) – chassis ground 20 – 60 Ω
PC400, 450-8R 35
Circuit diagram related to 2-stage relief solenoid of pump controller
36 PC400, 450-8R
Failure code [DWK0KB] 2-stage Relief Sol. S/C

User code Failure code 2-stage relief solenoid short
Trouble
— DWK0KB
Contents of
q Abnormal current flowed at output to 2-stage relief solenoid circuit.
trouble
Action of con- q Turns output to 2-stage relief solenoid circuit OFF.
Problem that
appears on q Power maximizing function does not work.
machine
Related infor- q Operating condition of 2-stage relief solenoid (ON/OFF) can be checked with monitoring function.

Defective 2-stage relief sole- without turning starting switch ON.
noid V08 (male) Resistance
1
2
value in normal (Short circuit with GND cir- Wiring harness between CP02 (female) Resis-
cuit) Min. 1 MΩ
state (109) – V08 (female) (2) and chassis ground tance
3 Defective pump controller When L-mode is not
Max. 1 V
Between (109) – selected
chassis ground When L-mode is
20 – 30 V
selected
PC400, 450-8R 37
Circuit diagram related to 2-stage relief solenoid of pump controller
38 PC400, 450-8R
Failure code [DXA0KA] PC-EPC Sol. Disc.

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

Defective PC-EPC solenoid
1
(Internal disconnection) V11 (male) Resistance
Between (1) – (2) 7 – 14 Ω
S21 Switch Resistance
Defective emergency pump
2 drive switch (Internal discon- OFF Max. 1 Ω
Between (2) – (3)
nection) ON Min. 1 MΩ
OFF Max. 1 Ω
Between (5) – (6)
ON Min. 1 MΩ
Possible causes
Max. 1 Ω
value in normal Disconnection in wiring har- – S21 (3) tance
state ness
Wiring harness between S21 (2) – V11 Resis-
(female) (1) tance
tor) Wiring harness between CP02 (female) Resis-
Max. 1 Ω
(115), (117), (120) – chassis ground tance
Max. 1 Ω
(female) (2) tance
4 Voltage Max. 1 V
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
Between (96) – (115), (117),
7 – 14 Ω
(120)
PC400, 450-8R 39
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
40 PC400, 450-8R
Failure code [DXA0KB] PC-EPC Sol. S/C

User code Failure code PC-EPC solenoid short
Trouble
E02 DXA0KB
Contents of
q Abnormal current flowed to PC-EPC solenoid circuit.
trouble
Action of con- q Sets output to PC-EPC solenoid circuit to 0.
Problem that
appears on q If pump load increases, engine speed lowers largely and engine may stall.
machine
q
Output to PC-EPC solenoid (current value) can be checked with monitoring function.
(Code 01300: PC-EPC solenoid current)
Related infor- q If solenoid and wiring harness are not defective, turn emergency drive switch on; the operator can
mation operate the machine with output equivalent to E-mode. (Failure code [DXA0KA] is then displayed,
but it is not defective.)
a Turn emergency pump drive switch OFF during troubleshooting.

Defective PC-EPC solenoid
1 (Internal short circuit or V11 (male) Resistance
Ground fault in wiring har- without turning starting switch ON.
and standard ness
value in normal 2 Wiring harness between CP02 (female) (96)
state cuit) – S21 – V11 (female) (1) and chassis Min. 1 MΩ
tance
ground
Between (96) – (115), (117),
7 – 14 Ω
(120)
PC400, 450-8R 41
42 PC400, 450-8R
Failure code [DXE0KA] LS-EPC Sol. Disc.

User code Failure code LS-EPC solenoid disconnection
Trouble
— DXE0KA
Contents of
q No current flows to LS-EPC solenoid circuit.
trouble
Problem that
q Travel speed Mi or Lo is high.
appears on
q Speed of work equipment and swing is high in lifting mode (L).
machine
Related infor- q Output to LS-EPC solenoid (current value) can be checked with monitoring function.
mation (Code 01500: LS-EPC solenoid current)

Defective LS-EPC solenoid
1
(Internal disconnection) V19 (male) Resistance
Between (1) – (2) 7 – 14 Ω
ness Max. 1 Ω
– V19 (female) (1) tance
Possible causes Wiring harness between CP02 (female) Resis-
and standard
tor) (115), (117), (120) – J05 and chassis ground tance
value in normal
state Max. 1 Ω
(female) (2) tance
3
Voltage Max. 1 V
Between (88) – (115), (117),
7 – 14 Ω
(120)
PC400, 450-8R 43
44 PC400, 450-8R
Failure code [DXE0KB] LS-EPC Sol. S/C

User code Failure code LS-EPC solenoid short
Trouble
— DXE0KB
Contents of
q Abnormal current flowed to LS-EPC solenoid circuit.
trouble
Action of con- q Sets output to LS-EPC solenoid circuit to 0.
Problem that
q Travel speed Mi or Lo is high.
appears on
q Work equipment speed and swing speed are high in lifting mode (L).
machine
Related infor- q Output to LS-EPC solenoid (current value) can be checked with monitoring function.
mation (Code 01500: LS-EPC solenoid current)

Defective LS-EPC solenoid
1 (Internal short circuit or V19 (male) Resistance
value in normal 2
Between (88) – (115), (117),
7 – 14 Ω
(120)
PC400, 450-8R 45
46 PC400, 450-8R
Failure code [DXE4KA] Service Current EPC Disc.

User code Failure code Service current EPC solenoid disconnection
Trouble
— DXE4KA
Contents of
q No current flows to service current EPC solenoid circuit.
trouble
Problem that
appears on q Attachment does not move.
machine
q Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related infor-
q Output to service current EPC solenoid (current value) can be checked with monitoring function.
mation
(Code 01700: Service solenoid current)

Defective service current without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) – (2) 7 – 14 Ω
ness
Possible causes – V30 (female) (1) tance
and standard tor) Wiring harness between CP02 (female) Resis-
value in normal Max. 1 Ω
(115), (117), (120) – V30 (female) (2) tance
state
3
Voltage Max. 1 V
Between (97) – (115), (117),
7 – 14 Ω
(120)
Circuit diagram related to service current EPC solenoid of pump controller
PC400, 450-8R 47
Failure code [DXE4KB] Service Current EPC S/C

User code Failure code Service current EPC solenoid short
Trouble
— DXE4KB
Contents of
q Abnormal current flowed to service current EPC solenoid circuit.
trouble
Action of con- q Sets output to service current EPC solenoid circuit to 0.
Problem that
appears on q Attachment does not move.
machine
q Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related infor-
q Output to service current EPC solenoid (current value) can be checked with monitoring function.
mation
(Code 01700: Service solenoid current)

Defective service current
1 EPC solenoid (Internal short V30 (male) Resistance
circuit or ground fault) Between (1) – (2) 7 – 14 Ω
value in normal 2
Between (97) – (115), (117),
7 – 14 Ω
(120)
Circuit diagram related to service current EPC solenoid of pump controller
48 PC400, 450-8R
Failure code [DY20KA] Wiper Working Abnormality

User code Failure code Wiper working abnormality
Trouble
— DY20KA (Pump controller system)
Contents of
q When windshield wiper works, W signal of working ends is not input.
trouble
Action of con- q Turns working output to wiper motor OFF.
Problem that
appears on q Wiper motor does not work.
machine
q Condition of W contact signal of wiper working area can be checked with monitoring function.
Related infor-
(Code: 02204 switch 5)
mation
q Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

M05 (female) Wiper blade Resistance
Defective wiper motor (Inter-
1 Operating range top Max. 1 Ω
nal disconnection)
Between (6) – (5) Other than operating
Min. 1 MΩ
range top
Between (1) – (3) All range Max. 20 Ω
Possible causes Max. 1 Ω
– M05 (male) (6) tance
and standard
ness (Disconnection in wir- Wiring harness between M05 (female) (5) – Resis-
value in normal 2 Max. 1 Ω
ing or defective contact in J04 – chassis ground (T05, T06) tance
state
connector)
Max. 1 Ω
(114) – M05 (male) (1) tance
Max. 1 Ω
(119) – M05 (male) (3) tance
CP01 (female) Wiper blade Resistance
3 Defective pump controller Operating range top Max. 1 Ω

sis ground Other than operating
Min. 1 MΩ
range top
Between (114) –
All range Max. 20 Ω
(119)
PC400, 450-8R 49
Circuit diagram related to wiper motor of machine monitor
50 PC400, 450-8R
Failure code [DY20MA] Wiper Parking Abnormality

User code Failure code Wiper parking abnormality
Trouble
— DY20MA
Contents of
q When windshield wiper parks, P signal of storage area is not input.
trouble
Action of con- q Turns parking output to wiper motor OFF.
Problem that
appears on q Wiper motor does not park.
machine
q Condition of P contact signal of wiper parking area can be checked with monitoring function.
Related infor-
(Code: 02204 switch 5)
mation
q Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.

M05 (female) Wiper blade Resistance
1
nal disconnection) Storage area Max. 1 Ω
Between (4) – (5)
Working area Min. 1 MΩ
Between (1) – (3) All range Max. 20 Ω
Max. 1 Ω
Possible causes – M05 (male) (4) tance
and standard ness (Disconnection in wir- Wiring harness between M05 (female) (5) – Resis-
value in normal 2 Max. 1 Ω
ing or defective contact in J04 – chassis ground (T05, T06) tance
state connector)
Max. 1 Ω
(114) – M05 (male) (1) tance
Max. 1 Ω
(119) – M05 (male) (3) tance
CP01 (female) Wiper blade Resistance
3 Defective pump controller Between (75) – chas- Storage area Max. 1 Ω
sis ground Working area Min. 1 MΩ
Between (114) –
All range Max. 20 Ω
(119)
PC400, 450-8R 51
52 PC400, 450-8R
Failure code [DY2CKB] Washer Drive Short

User code Failure code Window washer drive system short
Trouble
— DY2CKB
Contents of q When output to window washer drive system was turned ON (ground circuit was disconnected),
trouble short circuit was detected in circuit.
Action of con- q Turns output to washer motor OFF.
Problem that
appears on q Window washer does not operate.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
mation

Defective washer motor
1
(Internal short circuit) M06 (male) Resistance
Possible causes Between (1) – (2) 5 – 20 Ω
and standard
state Hot short (Short circuit with and carry out troubleshooting.
2
Voltage Max. 1 V
– J04 – M6 (female) (2), – D02 (female) (7)
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
PC400, 450-8R 53
Circuit diagram related to window washer motor of machine monitor
54 PC400, 450-8R
Failure code [DY2DKB] Wiper Drive (For) Short

User code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB
Contents of
q When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of con- q Turns output to wiper motor drive forward side OFF.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) Resistance
fault) Between (3) – (1) There is continuity
Possible causes
and standard Between (3) – chassis ground Min. 1 MΩ
state Ground fault in wiring har- without turning starting switch ON.
2 ness (Short circuit with GND
circuit) Wiring harness between CP02 (female) Resis-
Min. 1 MΩ
(119) – M05 (male) (3) tance
out.)
PC400, 450-8R 55
56 PC400, 450-8R
Failure code [DY2EKB] Wiper Drive (Rev) Short

User code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB
Contents of
q When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of con- q Turns output to wiper motor drive reverse side OFF.
Problem that
appears on q Windshield wiper does not operate.
machine
Related infor-
mation

1 nal short circuit or ground M05 (female) Continuity/Resistance
fault) Between (1) – (3) There is continuity
Possible causes
and standard Between (1) – chassis ground Min. 1 MΩ
state Ground fault in wiring har- without turning starting switch ON.
circuit) Wiring harness between CP02 (female) Resis-
Min. 1 MΩ
(114) – M05 (male) (1) tance
out.)
PC400, 450-8R 57
©2010 KOMATSU
All Rights Reserved
58
SEN04267-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting 1
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 system 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, 450-8R 1
E-13 Fuel level gauge does not indicate 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 and window washer do 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 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
E-32 Electric priming pump does not operate or does not stop automatically .............................................. 66
2 PC400, 450-8R
PC400, 450-8R 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.
Type of power
Fusible link Fuse No. Fuse capacity Destination of power
supply
1 10A Work lamp relay, emergency switch
2 30A Solenoid valve
Switch power F04 3 10A PPC oil pressure lock solenoid valve
supply (65A) Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Auto preheater
7 10A Beacon
Switch power F04 8 20A Working lamp (boom), working lamp (rear)
supply (65A) Radio
9 10A
Left knob switch (pump controller input)
10 20A (Spare)
11 20A Air conditioner unit
12 10A (Spare)
13 10A Headlamp
Switch power F04
supply (65A) 14 10A Optional power supply (1)
Travel alarm, 12 V power supply
15 20A Optional power supply (2), heated seat, air suspension
seat
Radio (backup power supply)
16 10A
Room lamp
Constant F05 Pump controller
17 20A
power supply (30A) Machine monitor
18 10A Electric priming pump
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
4 PC400, 450-8R
Location of fuse box and fuse Nos.
PC400, 450-8R 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 phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
<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.
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, 450-8R
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 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
Defective fuse No. 3, No. 17 fault.
2
or fusible link F04 and F05 In the case the machine monitor does not light up, check the power
circuit between the battery and the fuse.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Defective starting switch H15 (male) Position Resistance
3
OFF Min. 1 Mz
Between (1) – (4)
START Max. 1 z
Defective safety lock switch S14 (female) Lock lever Resistance
4
(internal short circuit)
Free Min. 1 Mz
Between (1) – (3)
Lock Max. 1 z
Possible causes
and standard
value in normal ing without turning starting switch ON.
Defective starting motor cut-
state out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistance
5
nal short circuit or ground Between (1) – (2) 100 – 500 z
fault)
Between (3) – (4) Min. 1 Mz
Between (3) – (6) Max. 1 z
(If power supply and starting input and output are normal but
starting motor does not turn, starting motor is defective.)
Defective starting motor
Starting
6 (Internal disconnection or Starting motor Voltage
switch
breakage)
Power supply: Between terminal
20 – 30 V
B and chassis ground When
Starting input: Terminal C – chas- started
20 – 30 V
sis ground
Defective alternator or start engine and carry out troubleshooting.
7
(Internal short circuit) Alternator Voltage
Terminal R – chassis ground Max. 1 V
PC400, 450-8R 7

Wiring harness between F01-17 – H15 Resis-
Max. 1 z
(female) (1) tance
Wiring harness between H15 (female) (4) – Resis-
Max. 1 z
J01 – R06 (female) (6) tance
Disconnection in wiring har- Wiring harness between R06 (female) (3) – Resis-
ness Max. 1 z
M17 (female) (1) tance
Wiring harness between F01-3 outlet – S14 Resis-
defective contact in connec- Max. 1 z
tor) (female) (1) tance
Wiring harness between S14 (female) (3) – Resis-
Max. 1 z
R06 (female) (1) tance
Wiring harness between R06 (female) (3) – Resis-
Max. 1 z
R07 (female) (4) tance
Max. 1 z
Possible causes
and standard
value in normal Wiring harness between battery relay termi-
Resis-
state nal B (R04) – F05 – F01-16D and chassis Min. 1 Mz
tance
ground
Wiring harness between F01-17 – H15 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Ground fault in wiring har- Wiring harness between H15 (female) (4) – Resis-
ness Min. 1 Mz
9 J01 – R06 (female) (6) and chassis ground tance
cuit) Wiring harness between R06 (female) (3) – Resis-
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
Min. 1 Mz
R06 (female) (1) and chassis ground tance
Min. 1 Mz
CM01 (female) (8) and chassis ground tance
10
24V circuit) in wiring harness Wiring harness between CM01 (female) (11)
– J02 – M17 (female) (2), – D01 (female) (6), Voltage Max. 1 V
– alternator terminal R and chassis ground
8 PC400, 450-8R
Circuit diagram related to engine start and battery charging
PC400, 450-8R 9
E-2 Auto-decelerator does not operate 1
Trouble • Auto-decelerator does not operate.

• Set speed of auto-decelerator is 1,300 rpm. Accordingly, set the fuel control dial to a higher rpm than
Related
this speed. If set speed is under 1,300 rpm, the auto-decelerator will not operate.
information
• Check all the monitoring indications after starting the engine.

In the case monitoring is not normally indicated, proceed to trouble-
shooting No. E-21.
Defective boom RAISE sig- Monitoring code Item Normal display
1
nal Operation of lever:
01900 Boom RAISE ON
Lever in neutral: OFF
shooting No. E-22.
Defective boom LOWER sig- Monitoring code Item Normal display
2
01900 Boom LOWER ON
shooting No. E-23.
Monitoring code Item Normal display
3 Defective arm IN signal
Operation of lever:
01900 Arm IN ON
Possible causes shooting No. E-24.
and standard
value in normal Monitoring code Item Normal display
4 Defective arm OUT signal
state Operation of lever:
01900 Arm OUT ON
shooting No. E-26.
Defective bucket CURL sig- Monitoring code Item Normal display
5
01901 Bucket CURL ON
shooting No. E-27.
Defective bucket DUMP sig- Monitoring code Item Normal display
6
01901 Bucket DUMP ON
shooting No. E-28.
7 Defective swing signal
Operation of lever:
01900 Swing ON
10 PC400, 450-8R

shooting No. E-29.
8 Defective travel signal
Operation of lever:
01900 Travel ON
Possible causes Lever in neutral: OFF
and standard In the case monitoring is not normally indicated, proceed to trouble-
value in normal shooting No. E-30.
state
9 Defective attachment signal
Operation of lever:
01901 Service ON
Since trouble is in system, troubleshooting cannot be carried out.
10 Defective pump controller (If causes 1 – 9 above are not detected, engine controller may be
defective.)
PC400, 450-8R 11
E-3 Automatic warming-up system 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-14.
Possible causes Defective engine coolant Monitoring code Item Normal display
1
and standard temperature signal Compare with actual
value in normal Engine coolant tem-
04102 engine coolant tem-
state perature
perature
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective pump controller causes stated above are not detected, engine controller may be
defective.)
12 PC400, 450-8R
PC400, 450-8R 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)
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes ness ing without turning starting switch ON.
value in normal defective contact in connec- Wiring harness between CM01 (female) (16) Resis-
Max. 1 z
tor) – J02 (male) (7) tance
state
a Prepare with starting switch OFF
CM01 Starting switch Voltage
Between (16) – chas- OFF Max. 1 V
sis 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 H15 (male) Starting switch Resistance
1
(Internal disconnection) OFF Min. 1 Mz
Between (1) – (3)
HEAT Max. 1 z
Defective heater relay ing without turning starting switch ON.
2
Possible causes (Internal disconnection) Heater relay Resistance
and standard Between (1) – (2) 300 – 600 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
Defective intake air heater ing without turning starting switch ON.
3
(Internal disconnection).
Between heater terminals Normal if conductive
Disconnection in wiring har- ing without turning starting switch ON.
ness
Wiring harness between H15 (female) (3) – Resis-
4 (Disconnection in wiring or Max. 1 z
J02 – Heater relay terminal R17 tance
tor) Wiring harness between battery relay termi- Resis-
Max. 1 z
nal M (R03) – Heater relay terminal R15 tance
14 PC400, 450-8R
Circuit diagram related to engine preheater
PC400, 450-8R 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 S14 (female) Lock lever Resistance
2
(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
Between (2) – chassis ground Min. 1 Mz
Defective assembled-type ing without turning starting switch ON.
Possible causes
4 diode D01
and standard D01 (male) Resistance
value in normal
Between (8) – (4) Min. 1 Mz
state
Disconnection in wiring har- Wiring harness between F01-3 outlet – S14 Resis-
ness Max. 1 z
(male) (1) tance
Wiring harness between S14 (male) (2) – Resis-
tor) J02 – V01 (male) (2) tance
Max. 1 z
ness Min. 1 Mz
6 (male) (1) and chassis ground tance
cuit) Wiring harness between S14 (male) (2) –
Resis-
J02 – V01(female) (2), – D01(female) (8) Min. 1 Mz
tance
and chassis ground
16 PC400, 450-8R
Circuit diagram related to PPC lock solenoid
PC400, 450-8R 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 P- 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
ness
Possible causes (female) (1) tance
and standard tor) Wiring harness between S11 (female) (2) – Resis-
value in normal Max. 1 z
CP01 (female) (41) tance
state
Ground fault in wiring har- ing without turning starting switch ON.
ness Wiring harness between F01-9 outlet – S11 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
CP01 (female) (41) and chassis ground tance
5 Defective pump controller CP01 Switch Voltage
Between (41) – chas- Released Max. 1 V
sis ground Pressed 20 – 30 V
Circuit diagram related to power max. switch
18 PC400, 450-8R
PC400, 450-8R 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

ness
Wiring harness between CM01(female) (1) Resis-
(2) – J06 tance
tor) Wiring harness between CM01 (female) (3), Resis-
Max. 1 z
(4) – chassis ground tance
Possible causes
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard
ness ing without turning starting switch ON.
value in normal 3
state (Short circuit with GND cir- Wiring harness between CM01(female) (1), Resis-
cuit) Min. 1 Mz
(2) – J06 and chassis ground tance
CM01 (female) Voltage/Resistance
4 Defective machine monitor Between (1), (2) – chassis
Voltage: 20 – 30 V
ground
Resistance: Max. 1 z
ground
20 PC400, 450-8R
Circuit diagram related to power source in monitor panel
PC400, 450-8R 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
[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
2 Defective machine monitor causes stated above are not detected, engine controller may be
defective.)
22 PC400, 450-8R
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 voltage)

Low fuel level
1 a Add fuel
(When system is normal)
Defective fuel level sensor P21 (male) Fuel level Resistance
2
Between (1) and FULL (Upper limit) Approx. 12 z
Possible causes chassis ground EMPTY (Lower limit) 85 – 110 z
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
state 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between CM01 (female) (9) – Resis-
Max. 1 z
tor) P21 (female) (1) tance

4 Defective machine monitor CM01 (female) Fuel level Resistance
Between (9) and FULL (Upper limit) Approx. 12 z
chassis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
PC400, 450-8R 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
Related function. (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.)

Defective coolant tempera- Engine coolant tem-
ture sensor TWTR (male) Resistance
1 perature
short circuit) Between (A) – (B) 90 – 3.5 kz
Between (A) – chas- 10 – 100°C
Min. 1 Mz
sis ground
ness
– TWTR (female) (A) tance
Possible causes tor) Wiring harness between TWTR (female) (B) Resis-
Max. 1 z
and standard – chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
ness
3
cuit) Min. 1 Mz
– TWTR (female) (A) and chassis ground tance
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
10 – 100°C 90 – 3.5 kz
sis ground
24 PC400, 450-8R
PC400, 450-8R 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
Trouble (C).
• 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 func-
information tion. (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) – chas- 10 – 100°C
Min. 1 Mz
sis ground
ness
tor) Wiring harness between CP01 (female) (46) Resis-
Possible causes Max. 1 z
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
state ness ing without turning starting switch ON.
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
Engine coolant tem-
CP01 Resistance
5 Defective machine monitor perature
Between (29) – (46) 90 – 3.5 kz
Between (29) – chas- 10 – 100°C
Min. 1 Mz
sis ground
Circuit diagram related to hydraulic oil temperature sensor
26 PC400, 450-8R
E-13 Fuel level gauge does not indicate 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. (Code
information 04200: Fuel level sensor voltage)

Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) Between (1) – chas- FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
defective contact in connec- Wiring harness between CM01 (female) (9) – Resis-
Max. 1 z
tor) P21 (female) (1) tance
Possible causes
and standard Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
3
state (Short circuit with GND cir- Wiring harness between CM01 (female) (9) – Resis-
cuit) Min. 1 Mz
4
24V circuit) in wiring harness Wiring harness between CM01 (female) (9) –
Voltage Max. 1 V
P21 (female) (1) and chassis ground
5 Defective machine monitor CM01 Fuel level Resistance
Between (9) – chas- FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
PC400, 450-8R 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 OFF, swing lock monitor lights up.
Related • Input from swing lock switch (ON/OFF) can be checked with monitoring function.
information (Code 04502: Monitor Input 3)

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
ness
Wiring harness between CM02 (female) (5) – Resis-
J02 – S04 (male) (5) tance
tor) Wiring harness between S04 (male) (6) – Resis-
and standard
3
(Short circuit with GND cir- Wiring harness between CM02 (female) (5) – Resis-
cuit) Min. 1 Mz
J02 – S04 (male) (5) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CM02 (female) (5) –
Voltage Max. 1 V
J02 – S04 (male) (5) and chassis ground
5 Defective machine monitor CM02 Swing lock switch Voltage
Between (5) – chas- OFF 20 – 30 V
sis ground ON Max. 1 V
28 PC400, 450-8R
Circuit diagram related to swing lock switch
PC400, 450-8R 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-21.
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, 450-8R
PC400, 450-8R 31
E-16 Windshield wiper and window washer do not operate 1
Trouble (1) When wiper switch is operated, wiper monitor does not light up or go off.
Related • Condition of wiper switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, trou-
state bleshooting cannot be carried out.)
Trouble (2) When wiper switch is operated, wiper does not operate.
Related • Condition of window rear limit switch signal can be checked with monitoring function.
information (Code: 02204 Switch input 5)

W03 (male) Front window Resistance
Defective window rear limit
1 When installed to
switch (Internal short circuit) Min. 1 Mz
front
Between (1) – (2)
When retracted to
Max. 1 z
rear
Defective wiper motor (Inter- ing without turning starting switch ON.
2
nal disconnection) M05 (female) Continuity
Between (1) – (3) There is continuity
ness (Disconnection in wiring Wiring harness between CP02 (female) Resis-
Possible causes 3 Max. 1 z
or defective contact in con- (119) – M05 (male) (3) tance
and standard nector) Wiring harness between CP02 (female) Resis-
value in normal Max. 1 z
state (114) – M05 (male) (1) tance
circuit) Resis-
CP01 (female) (57) – W03 (male) (1) Min. 1 Mz
tance
CP01 (female) Front window Resistance
Defective pump controller
(Rear limit switch system) When installed to
Min. 1 Mz
Between (57) – front
5 chassis ground When retracted to
Max. 1 z
rear
Defective pump controller ing without turning starting switch ON.
(Wiper motor system) CP02 (female) Continuity
Between (119) – (114) There is continuity
32 PC400, 450-8R
Circuit diagram related to windshield wiper motor
PC400, 450-8R 33
Trouble (3) When window washer switch is operated, window washer does not operate.
Related • Condition of window washer switch signal can be checked with monitoring function.
information (Code: 04504 Monitor 1st, 2nd line switches)

and standard
value in normal Machine monitor may be defective. (Since trouble is in system, trou-
state bleshooting cannot be carried out.)
Circuit diagram related to window washer motor of machine monitor
34 PC400, 450-8R
PC400, 450-8R 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 switch (Internal disconnec- S05 (female) Resistance
switch
tion)
Low pressure set Max. 1 z
Between (5) – (6)
High pressure set Min. 1 Mz
Defective machine push-up ing without turning starting switch ON.
3
short circuit or ground fault) Between (1) – (2) 20 – 60 z
Between (2) – chassis ground Min. 1 Mz
Defective assembled-type ing without turning starting switch ON.
Possible causes
4 diode D02
and standard D02 (male) Resistance (Continuity)
value in normal
Between (2) – (6) Min. 1 Mz (without continuity)
state
Disconnection in wiring har- Wiring harness between F01-2 outlet – S05 Resis-
ness Max. 1 z
(male) (1) tance
Wiring harness between S05 (male) (2) – Resis-
tor) J01 – V06 (female) (6) tance
Max. 1 z
Ground fault in wiring har- Wiring harness between F01-2 outlet – S05
Resis-
ness (male) (5), – other harnesses between Min. 1 Mz
6 tance
(Short circuit with GND cir- related circuits and chassis ground
cuit)
Wiring harness between S05 (male) (6) –
Resis-
J01 – V06 (female) (2), – D02 (female) (2) Min. 1 Mz
tance
and chassis ground
36 PC400, 450-8R
• 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 (5) – (6)
High pressure set Min. 1 Mz
state
2
24V circuit) in wiring harness Wiring harness between S05 (male) (6) –
J01 – V06 (female) (2), – D02 (female) (2) Voltage Max. 1 V
and chassis ground
Circuit diagram related to machine push-up solenoid
PC400, 450-8R 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 out troubleshooting.
oil pressure switch (Internal P06 (male) Boom lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom RAISE Max. 1 z
ness
tor) Wiring harness between P06 (female) (1) – Resis-
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP01 Boom lever Voltage
Between (53) – chas- Neutral 20 – 30 V
sis ground Boom RAISE Max. 1 V
38 PC400, 450-8R
Circuit diagram related to boom RAISE PPC oil pressure switch
PC400, 450-8R 39
E-19 Monitoring function fails to display “boom lower” normally 1
• Boom LOWER operation is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
Related
• Monitoring code: 01900 (Output Switch 1)
information

Defective boom LOWER out troubleshooting.
PPC oil pressure switch P02 (male) Boom lever Resistance
1
short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom LOWER Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP01 Boom lever Voltage
sis ground Boom LOWER Max. 1 V
40 PC400, 450-8R
Circuit diagram related to boom LOWER PPC oil pressure switch
PC400, 450-8R 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 out troubleshooting.
sensor P04 (male) Voltage
1
short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
Between (19) – (18) 4.5 – 5.5 V
Between (17) – (18) 0.5 – 4.5 V
Circuit diagram related to arm IN PPC oil pressure switch
42 PC400, 450-8R
PC400, 450-8R 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)
Arm OUT Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP01 Arm lever Voltage
sis ground Arm OUT Max. 1 V
44 PC400, 450-8R
Circuit diagram related to arm OUT PPC oil pressure switch
PC400, 450-8R 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
• Monitoring code:01901 (Output Switch 2)
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 – 4.5V
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
a :Prepare with starting switch OFF, then turn starting switch ON
Between (19) – (18) 4.5 – 5.5V
Between (73) – (18) 0.5 – 4.5V
Circuit diagram related to Bucket CURL PPC oil pressure switch
46 PC400, 450-8R
PC400, 450-8R 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 out troubleshooting.
oil pressure switch (Internal P05 (male) Bucket lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Bucket DUMP Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP01 Bucket lever Voltage
sis ground Bucket DUMP Max. 1 V
48 PC400, 450-8R
Circuit diagram related to bucket DUMP PPC oil pressure switch
PC400, 450-8R 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 har- Wiring harnesses between CP01 (female) Resis-
ness Max. 1 z
(16) – P03 (male) (2), – P07 (female) (2) tance
Possible causes 3 (Disconnection in wiring or
and standard defective contact in connec- Max. 1 z
tor) chassis ground tance
value in normal
state Max. 1 z
ness
4 Wiring harnesses between CP01 (female)
cuit) (16) – P03 (female) (2), – P07 (female) (2) Min. 1 Mz
tance
and chassis ground
5
24V circuit) in wiring harness Wiring harnesses between CP01 (female)
(16) – P03 (female) (2), – P07 (female) (2) Voltage Max. 1 V
and chassis ground
6 Defective pump controller CP01 Bucket lever Voltage
sis ground Left or Right Max. 1 V
50 PC400, 450-8R
Circuit diagram related to right and left swing PPC oil pressure switches
PC400, 450-8R 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 oil out troubleshooting.
pressure switch P09 (male) Travel lever Resistance
1
Between (1) – (2)
Forward or reverse Max. 1 z
ness
– J01 – P09 (female) (2) tance
Max. 1 z
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness
state 3 Wiring harness of CP01 (female) (55) – J01
cuit) – P09 (female) (2), – M14 (female) (2) and Min. 1 Mz
tance
chassis ground
4
24V circuit) in wiring harness Wiring harness of CP01 (female) (55) – J01
– P09 (female) (2), – M14 (female) (2) and Voltage Max. 1 V
chassis ground
sis ground Forward or reverse Max. 1 V
52 PC400, 450-8R
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-8R 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 out troubleshooting.
PPC oil pressure switch P10 (male) Travel lever Resistance
1
Between (1) – (2)
Left or right only Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
sis ground Left or right only Max. 1 V
54 PC400, 450-8R
Circuit diagram related to travel steering PPC oil pressure switch
PC400, 450-8R 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 service (front) PPC out troubleshooting.
oil pressure switch P14 (male) Service pedal Resistance
1
Between (1) – (2)
Front Max. 1 z
Defective service (rear) PPC out troubleshooting.
oil pressure switch P15 (male) Service pedal Resistance
2
Between (1) – (2)
Rear Max. 1 z
ness Max. 1 z
– P14 (female) (2), – P15 (female) (2) tance
Possible causes 3 (Disconnection in wiring or
and standard defective contact in connec- Max. 1 z
tor) chassis ground tance
value in normal
state Max. 1 z
ness
4 Wiring harness between CP01 (female) (52)
cuit) – P14 (female) (2), – P15 (female) (2) and Min. 1 Mz
tance
chassis ground
5
– P14 (female) (2), – P15 (female) (2) and Voltage Max. 1 V
chassis ground
6 Defective pump controller CP01 Service pedal Voltage
sis ground Front or rear Max. 1 V
56 PC400, 450-8R
Circuit diagram related to service PPC oil pressure switch
PC400, 450-8R 57
E-28 KOMTRAX system does not operate normally 1

Trouble • KOMTRAX system does not operate normally.
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related carry out following troubleshooting.
information • Even if KOMTRAX system has trouble, it does not particularly appear on machine.
• Carry out all troubleshooting on service menu screen of machine monitor.

a Turn starting switch ON and check “Setting condition or termi-
nal” screen.
1 Defective communication 1
Check item Normal display
Communication start check Completion
a Turn starting switch ON and check “Condition of positioning and
communication” screen.
N ###,##,## (Latitude)
2 Defective GPS
Positioning E ###,##,## (Longitude)
Possible causes
In positioning
and standard
value in normal If latitude and longitude are not displayed in 5 minutes on open
state ground, notify KOMTRAX service hot line.
Defective communication Check item Normal display
3
environment Communication Zone level 1 – Zone level 3
If zone level 1 – 3 is not displayed within communication zone of
ORBCOMM, notify KOMTRAX service hot line.
4 Defective communication 2
Number of items not transmitted 0 – 9 (Normally 0)
a Select “Terminal Status” from “12 Display of a Select “GPS & Communication Status” from
KOMTRAX setting” in the service menu of the “12 Display of KOMTRAX setting” in the ser-
machine monitor. vice menu of the machine monitor.
58 PC400, 450-8R
PC400, 450-8R 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 troubleshoot-
switch ing without turning starting switch ON.
2
(Internal disconnection or P17 (male) Resistance
defective contact) Between (1) – (2) Max. 1 z
Wiring harness between F01-11 outlet – Resis-
Disconnection in wiring har- Max. 1 z
AC01 (male) (4) tance
ness
Wiring harness between M26 (male) (7) – Resis-
P17 (female) (1) tance
Possible causes defective contact in connec-
tor) Wiring harness between AC01 (male) (5) – Resis-
and standard Max. 1 z
value in normal chassis ground tance
state Wiring harness between P17 (female) (2) – Resis-
Max. 1 z
ness Wiring harness between F01-11 outlet – Resis-
4 Min. 1 Mz
(Short circuit with GND cir- AC01 (male) (4) and chassis ground tance
cuit)
Wiring harness between M26 (male) (7) – Resis-
Min. 1 Mz
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
AC01 Voltage
Between (1) – (3) 20 – 30 V
60 PC400, 450-8R
Circuit diagram related to air conditioner
PC400, 450-8R 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-21.
2 Defective travel signal Operation of lever:

019 Travel ON
When the monitoring display is not correct, proceed to diagnosis for
“'Travel is not normally indicated' in the monitoring function”
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)
Operated 20 – 30 V
value in normal
state If above voltage is normal and travel alarm does not sound, travel
alarm is defective.
ness
Wiring harness between F01-15 outlet – J03 Resis-
– M14 (female) (1) tance
tor) Wiring harness between M14 (female) (2) – Resis-
Max. 1 z
J01 (19) tance
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
5
(Short circuit with GND cir- Wiring harness between F01-15 outlet – J03 Resis-
cuit) Min. 1 Mz
– M14 (female) (1) and chassis ground tance
6 Defective pump controller causes 1 – 5 above are not detected, travel alarm may be defec-
tive.)
62 PC400, 450-8R
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-8R 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 troubleshoot-
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 troubleshoot-
Possible causes ing without turning starting switch ON.
and standard Resis-
Between M08 (female) (1) – chassis ground Max. 1 z
value in normal tance
state If above is normal, the horn is defective
Disconnection in wiring har- Wiring harness between F01 (5) – S10 Resis-
ness Max. 1 z
(female) – R08 (female) (3) tance
tor) R08 (female) – M07 (female) (2) tance
Max. 1 z
M08 (female) (2) tance
Wiring harness between F01 (5) – S10
Resis-
Ground fault in wiring har- (female) – R08 (female) (3) and chassis Min. 1 Mz
tance
ness ground
6
(Short circuit with GND cir- Wiring harness between S10 (female) (2) –
cuit) Resis-
R08 (female) – M07 (female) (2) and chassis Min. 1 Mz
tance
ground
Min. 1 Mz
M08 (female) (2) and chassis ground tance
64 PC400, 450-8R
Circuit diagram related to horn
PC400, 450-8R 65
E-32 Electric priming pump does not operate or does not stop
automatically 1
Failure
• Electric priming pump does not operate or does not stop automatically
phenomenon
Relative
information
Cause Standard value in normalcy and references for troubleshooting

1 Low battery charge level Battery charge level may be low. Check battery directly.
2 Defective fuse No.18 If fuse is broken, circuit probably has ground fault.
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it
harness (Power supply and carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring or
defective contact in con- Between S50 (1) – (2) Voltage 20 – 30 V
nector)
a Prepare with battery ground cable disconnected, then connect bat-
tery and turn electric priming pump ON and carry out troubleshoot-
ing.
Disconnection in wiring
harness (Drive power sup- • Lamp blinks but stops in about 5 seconds.
ply system) Between M37 (1) – (2) Voltage 20 – 30 V
4
(Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out
defective contact in con-
troubleshooting without reconnecting (since power supply is
nector)
unswitched).
Resis-
Between S50 (female) (2) – ground Max. 1 z
tance
a Prepare with battery ground cable disconnected, then carry out
Presumed cause
and
unswitched).
standard value in
normalcy Wiring harness between S50 (female) (1) – fus- Resis-
Min. 1 Mz
Ground fault in wiring har- ible link F05 and ground tance
5 ness (Contact with GND Wiring harness between S50 (female) (3) – M37 Resis-
Min. 1 Mz
circuit) (female) (1) and ground tance
Wiring harness between S50 (female) (4) – M37 Resis-
Min. 1 Mz
(female) (2) and ground tance
Resis-
Between M37 (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect bat-
tery and turn electric priming pump ON and carry out troubleshoot-
ing.
Between S50 (3) – (4) Voltage 20 – 30 V
Defective electric priming
6 pump switch (Malfunction • Lamp blinks but output voltage is improper.
or automatic stop failure) • Results of troubleshooting steps 1 – 4 are normal and lamp does not
blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric prim-
7 a If pump is overloaded, power supply is turned OFF automatically to
ing pump
protect circuit (Priming switch is reset automatically).
66 PC400, 450-8R

a Prepare with battery ground cable disconnected, then carry out
Presumed cause unswitched).
and Resis-
Between M37 (male) (1) – (2) 1–3z
standard value in 8 Trouble in electric priming tance
normalcy pump
Resis-
Between M37 (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between M37 (male) (2) – pump body Min. 1 Mz
tance
Circuit diagram related to electric priming pump
PC400, 450-8R 67
SEN04267-01

© 2010 KOMATSU
All Rights Reserved
68
SEN04268-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting 1
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, 450-8R 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, 450-8R
PC400, 450-8R 3
System chart for hydraulic and mechanical system 1
4 PC400, 450-8R
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, 450-8R 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
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, 450-8R
PC400, 450-8R 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
pressure (Approx. 3/5)
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 Lifting operation 0 MPa {0 kg/cm2}
8 PC400, 450-8R

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, 450-8R 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, 450-8R
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 Safety 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

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, 450-8R 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, 450-8R
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, 450-8R 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
Possible causes divider valve (main/LS) function. Check it directly.
and standard Malfunction of arm control Spool of arm control valve (Lo/Hi) may have malfunction. Check it
value in normal 4
state
Malfunction of arm control
Pressure compensation valve of arm control valve (Lo/Hi) may have
malfunction. Check it directly.
tion valve)
Malfunction of arm control Regeneration valve of arm control valve (Lo) may have malfunction
6
valve (regeneration valve) or defective seal. Check it directly.
Safety-suction valve of arm control valve (Lo/Hi) may have malfunc-
7 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.
8
valve (quick return valve) Check it directly.
Malfunction of LS shuttle LS shuttle valve of right travel control valve, boom control valve, left
9 valve (right travel, boom, left travel control valve, bucket control valve, or service control valve
travel, bucket, or service) may have malfunction. Check it directly.
10 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, 450-8R
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.
Trouble • Work equipment does not move singly (2) Arm does not move singly.
(3) Bucket does not move singly.
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, 450-8R 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, 450-8R
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, 450-8R 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 Lifting operation 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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 travel control LS shuttle valve of travel control valve may have malfunction. Check
7
valve (LS shuttle valve) it directly.
8 Defective travel motor
Travel lever Leakage from travel motor
22 PC400, 450-8R
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, 450-8R 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
selector 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, 450-8R
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, 450-8R 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, 450-8R
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, 450-8R 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, 450-8R
(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, 450-8R 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 Swing control valve spool may be malfunctioning. 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, 450-8R
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, 450-8R 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, 450-8R
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
carry out troubleshooting.
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, 450-8R 33
SEN04268-01

© 2010 KOMATSU
All Rights Reserved
34
SEN04269-01
PC400, 450-8R
SEN04269-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 and up
40 Troubleshooting
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart........................................................................................................ 3

S-1 Starting performance is poor ................................................................................................................ 6
S-2 Engine does not start ........................................................................................................................... 7
S-3 Engine does not pick up smoothly........................................................................................................ 10
S-4 Engine stops during operations ............................................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................. 18
S-12 Oil pressure drops .............................................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel)............................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................................... 21
S-15 Abnormal noise is made..................................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................................... 24
PC400, 450-8R 1
2 PC400, 450-8R
Method of using troubleshooting chart
The troubleshooting chart consists of the "ques-

tions", "check items", "causes", and "troubleshoot-
ing" 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 nar-
row 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 prob-
able 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 Q
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.)
PC400, 450-8R 3
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of "Exhaust gas color is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became
black], [Power slowly became weaker], and [Dust indicator is lighting red].
4 PC400, 450-8R
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
PC400, 450-8R 5
S-1 Starting performance is poor

General causes why starting performance is poor Cause
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
q Defective electrical system
Defective alternator (generator section)

Defective alternator (regulator section)
q Insufficient supply of fuel
Stuck, seized supply pump plunger

q
Defective intake air heater system

Insufficient intake of air
Defective or deteriorated battery

q
Clogged feed pump gauze filter

Improper selection of fuel
q
Clogged air cleaner element

Coolant in exhaust piping
Clogged fuel filter/strainer

Worn piston ring, cylinder
a The common rail fuel injection system (CRI) recognizes the fuel injection timing
electrically. Accordingly, even if the starting operation is carried out, the engine may
Defective injector
not start until the crankshaft revolves 2 turns at maximum. This phenomenon does
not indicate a trouble, however.
Confirm recent repair history

Degree of use of
machine
Operated for long period E EE E
Starting perfor- Became worse gradually Qww QQ
mance Engine starts easily when warm w w
Questions
Non-specified fuel is being used QQQQ

Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
w wwQQ
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
installed)
ww
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
Starting motor cranks engine slowly w
Check items
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
ww
cranked with start- out
ing motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
w
Engine does not pick up smoothly and combustion is irregular QQ w
There is hunting from engine (rotation is irregular) QwQQ
Blow-by gas is excessive w
Inspect air cleaner directly q
When compression pressure is measured, it is found to be low qq
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect gauze filter of feed pump directly q

Carry out troubleshooting for "Rail Press (Very) Low Error. (*2)" See *2 for failure
code.
q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q
When starting switch is turned to HEAT, intake air heater mount does not become
warm
q
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
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 PC400, 450-8R
S-2 Engine does not start

a) Engine does not turn Cause
Defective starting motor (safety relay section)

General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Internal parts of engine seized:
See "S-4 Engine stops during operations"
Defective or deteriorated battery

q Coolant entered in cylinder, producing water hammer
Defective starting circuit wiring

q Defective electrical system
q Defective hydraulic pump
Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Questions
Degree of use of
Operated for long period EE
machine
Condition of horn Horn does not sound Q Q w
when starting switch
Horn volume is low w
is turned ON
Battery electrolyte is low w
Battery terminal is loose w
Check items
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 w w
When starting switch Speed of rotation is low w
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 Q Qw
Inspect flywheel ring gear directly q
Carry out troubleshooting in H-mode

Carry out troubleshooting in E-mode
When specific gravity of electrolyte and voltage of battery are measured, they are low q
There is not voltage (20 – 30 V) between battery relay terminal
q
M and terminal E
Troubleshooting
When terminal B and terminal C of starting switch are con-

q
nected, engine starts
Turn starting switch When terminal B and terminal C at safety relay outlet are con-
OFF, connect cord, q
nected, engine starts
and carry out trouble-
shooting at ON
Even if terminal B and terminal C at safety relay outlet are con-
q
nected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Correct
―
―
Remedy
PC400, 450-8R 7
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
q Fuel is not being supplied

q Supply of fuel is extremely small

q 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
Questions
Degree of use of
Operated for long period EEE
machine
Exhaust smoke suddenly stopped coming out (when starting again) wQwww EE
Replacement of filters has not been carried out according to Operation
ww E Q
and Maintenance Manual
When fuel tank is inspected, it is found to be empty w
QQQ QQ
Check items
Rust and water are found when fuel tank is drained

When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping wQQ
If air bleeding plug of fuel filter is removed, fuel does
While engine is Q Q wQ
not flow out
cranked with
If spill hose from injector is disconnected, little fuel
starting motor Q wwww Q
spills
Inspect fuel filter directly q
Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting for "Rail Press (Very) Low Error. (*1)" See *1
qq q q
for failure code.
Carry out troubleshooting for "PCV1 Error (*2) or PCV2 Error (*3)." See
q
*2 or *3 for failure code.
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode qq
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure codes [CA559] and [CA2249]

8 PC400, 450-8R
c) Exhaust smoke comes but engine does not start Cause

(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
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

q Lack of rotating force due to defective electrical system

q Insufficient intake of air

q Improper selection of fuel
Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel
Degree of use of
Operated for long period E EE E
machine
w w Q
Questions
Suddenly failed to start

Non-specified fuel is being used QQ
Replacement of filters has not been carried out according to Operation and
w ww
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does
w
not 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 ww
When fuel filter is removed, there is not fuel in it w
w
Check items
Fuel is leaking from fuel piping

Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
While engine is If air bleeding plug of fuel filter is removed, fuel does not
Q ww
cranked with start- flow out
ing motor 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
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 fail-
q
ure code.
When injector is tested alone, condition of spray is poor q
When specific gravity of electrolyte and voltage of battery are measured, they
q
are low
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
q
become warm
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
PC400, 450-8R 9
S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly Cause
Malfunction of flow damper (Leakage from injector is large)

q Defective condition of fuel injection
Seized turbocharger, interference of turbocharger

q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray


Improper valve clearance
Degree of use of
machine
Operated for long period EE E EE
Questions
Engine pick-up suddenly became worse w QQ Q

Non-specified fuel is being used www w
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual
w ww
Rust and water are found when fuel tank is drained ww
Fuel is leaking from fuel piping w
When exhaust manifold is touched immediately after starting engine, temperature of
Q w
Check items
some cylinders is low

Color of exhaust Blue under light load w
gas Black wQ 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
applied
Q ww
There is hunting from engine (rotation is irregular) Q Qw Q
When compression pressure is measured, it is found to be low q q
q
Troubleshooting
Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *2 for failure
code.
q
not change
qq
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 PC400, 450-8R
S-4 Engine stops during operations

General causes why engine stops during operations Cause
Broken dynamic valve system (valve, rocker arm, etc.)

q Seized parts inside engine
q There is overheating
q 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
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
Replacement of filters has not been carried out according to Operation and Mainte- w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Check items
Rust and water are found when fuel tank is drained w w

Metal particles are found when oil pan is drained 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
q
Carry out troubleshooting in H-mode
Inspect dynamic valve system directly

Inspect piston, connecting rod directly q
Inspect crank shaft bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
q q
Carry out troubleshooting for "Rail Press (Very) Low Error. (*1)" See *1 for code.
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, 450-8R 11
S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly Cause
Malfunction of flow damper (Leakage from injector is large)

q Air in fuel system
q Defective speed sensor (Error at degree that it is not indicated)
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

Degree of use of
machine
Questions
Occurs at a certain speed range 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
Occurs on slopes w Q Q
w w
Maintenance Manual
Check items

Rust and water are found when fuel tank is drained Q Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change
Carry out troubleshooting for "Eng Ne Speed Sensor Error. (*1)" See *3 for
q
failure code.
Carry out troubleshooting for "Eng Bkup Speed Sensor Error. (*2)" See *4 for
q
failure code.
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
*1: Failure code [CA689]

*2: Failure code [CA778]
12 PC400, 450-8R
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output Cause
Defective installation of charge air pressure sensor (air leakage)

q Defective condition of fuel spray
Defective charge air pressure sensor, wiring harness

Defective fuel temperature sensor, wiring harness

Clogged injector, defective spray (dirt in injector)

q There is overheating:
See "S-14 Coolant temperature becomes too high (Overheating)"
Defective drive of injector (signal, solenoid)

q

Controller is controlling in derate mode


Air leakage from air intake piping

Leaking, clogged fuel piping

Degree of use of machine Operated for long period E E E EE
Questions
Suddenly Q QQQ
Power was lost
Gradually Q Q Q QQ Q Q
Non-specified fuel is being used QQ
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Engine oil must be added more frequently QQQ
Output becomes insufficient after short stop of operation w
Black ww
Color of exhaust gas
w
Check items
Blue under light load

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is
low w
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is applied wwQ
Engine does not pick up smoothly and combustion is irregular w QQ w
There is hunting from engine (rotation is irregular) QQQQ
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low qqq
q q
Troubleshooting
When compression pressure is measured, it is found to be low

Inspect valve clearance directly q
Carry out troubleshooting for "Rail Press (Very) Low Error. (*1)" See *1 for failure code. q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change qq
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, 450-8R 13
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black Cause
Leakage of air between turbocharger and cylinder head


q Supply of fuel is excessive
q Defective condition of fuel spray

q
Clogged spill piping (on cylinder head side)

Improper selection of fuel

q There is overheating:
See "S-14 Coolant temperature becomes too high (Overheating)"

q Controller is controlling in derate mode
Improper fuel injection pressure

Improper fuel injection timing

Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Degree of use of
machine
Operated for long period E E E E
Suddenly became black w Q Q
Questions
Color of exhaust
gas
Gradually became black w Q Q Q
Black during light-load operation w
Non-specified fuel is being used Q Q
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, tempera-
Q w
Check items
ture of some cylinders is low

Torque converter stall occurred or pump relief speed is high (Fuel is injected
excessively)
Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular 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. (*1)" See *2 for fail-
ure code.
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
q
Inspect spill piping (on cylinder head side) directly q
Carry out troubleshooting for "Coolant Temp Sens High (Low) Error. (*2)" See *3
for code.
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

14 PC400, 450-8R
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive Cause
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Abnormal consumption of oil
Worn, damaged valve (stem, guide, seal)

q Long-time operation of engine at low idle or high idle (Do not run engine
at idle for more than 20 minutes continuously)
Dust sucked in from intake system

q External leakage of oil
Clogged breather, breather hose

q Wear of parts in lubrication system
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

EEE E
Questions
Degree of use of
Operated for long period
machine
Oil consumption suddenly increased w Q
Oil must be added more frequently 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
Check items
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w

There is oil in coolant w
Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Amount of blow-by Excessive Q Q w w
gas None w
When intake manifold is removed, dust is found inside q
q
Troubleshooting
When intake manifold is removed, inside is found to be dirty abnormally

Excessive play of turbocharger shaft q 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
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC400, 450-8R 15
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Cause
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q
Clogged breather, breather hose

Use of improper oil
q
Defective oil filter safety valve

Operation under excessive load
Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use of
EEE
Questions

machine
Non-specified fuel is being used Q
Oil filter clogging monitor indicates error even when oil temperature is high (if monitor
w Q
is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Check items
Engine oil temperature rises quickly w

Blue under light load w
Color of exhaust gas
Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q
Troubleshooting

q
See S-7
Check breather and breather hose directly
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
Clean
Clean
Clean
―
Remedy
16 PC400, 450-8R
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Cause

q Leakage of fuel
q Defective condition of fuel injection (fuel pressure, injection timing)
q 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

Questions
Degree of use of
Operated for long period EE E
machine
More than for other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
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
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Low idle speed is high Q
Torque converter stall occurred or oil pressure pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q
Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting for "Rail Press (Very) Low Error. (*1)" See *2 for failure
q
code.
q
not 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
q
failure code.
Check with monitoring function of the machine monitor. q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

PC400, 450-8R 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
General causes why oil is in coolant Cause
Broken O-ring of cylinder liner, holes caused by pitting

q Internal leakage in lubrication system
q 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
Degree of use of
E E
Questions

machine
Suddenly occurred Q Q
Increase of oil level
Gradually occurred Q Q
Hard water is being used as coolant Q Q
Q Q w
Troubleshooting Check items
Oil level has risen, oil is milky
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
18 PC400, 450-8R
S-12 Oil pressure drops

General causes why oil pressure drops Cause
Defective oil pressure sensor, wiring harness

Leaking, crushed, clogged hydraulic piping
q Leakage, clogging, wear of lubrication system
Defective oil level sensor, wiring harness

q Defective oil pressure control
q Improper selection of oil (improper viscosity)
q Selection of oil by the temperature etc. specified in the Operation and Mainte-
nance Manual is not observed.
Clogged, broken pipe in oil pan
Defective oil pump relief valve

q Deterioration of oil due to overheating
Clogged strainer in oil pan

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
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
Oil pressure Indicates pressure drop at low idle w Q
monitor Indicates pressure drop at low, high idle Q w w w Q
(if monitor is Indicates pressure drop on slopes w
Check items
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
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
Metal particles are found in oil filter q
q q
Troubleshooting
Inspect oil pan strainer, pipe directly

Oil pump rotation is heavy, there is play in oil pump q
See S-13
Valve spring of oil pump relief valve is fatigued, damaged q

Inspect oil filter 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
Correct
Adjust
Clean
Clean
―
Remedy
Add
PC400, 450-8R 19
S-13 Oil level rises (Entry of coolant or fuel)

General causes why oil level rises Cause
Clogging or defective seal of water pump drain hole (breather hole)

q Coolant in oil (milky)
q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in coolant"

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 E E E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q w
Q
Check items
When engine is started, drops of water come from muffler

When radiator cap is removed and engine is run at low idle, an abnormal number
w Q
of bubbles appear, or coolant spurts back
Exhaust smoke is white Q Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned up, water comes out w
Oil level in clutch or damper chamber of machine is low w
Oil level in hydraulic tank of applicable machine is low
q
Troubleshooting
Remove and inspect head cover directly

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
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20 PC400, 450-8R
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too high Cause

q Lack of cooling air (deformation, damage of fan)
q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Rise in hydraulic oil temperature
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
Operated for long period E E E E
Questions
of machine
Condition of Suddenly overheated Q w Q
overheating Always tends to overheat Q w w Q
Coolant temper- Rises quickly Q w
ature gauge
Does not go down from red range w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
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
Check items
Milky oil is floating on coolant w

There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are
w w
clogged 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 cylinder liner directly q
Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is
Troubleshooting
q
large
When operation test of thermostat is carried out, it does not open at
q
cracking temperature
Temperature difference between upper and lower tanks of radiator is
q
slight
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
Correct
Correct
Correct
Remedy
Add
PC400, 450-8R 21
S-15 Abnormal noise is made

General causes why abnormal noise is made Cause
Improper fuel injection timing (abnormality in coolant low

Deformed cooling fan, loose fan belt, interference of fan
Leakage of air between turbocharger and cylinder head
q Abnormality due to defective parts
Defective inside of muffler (dividing board out of posi-

q Abnormal combustion
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
q Air sucked in from intake system

a Judge if the noise is an internal noise or an external noise before starting
troubleshooting.
a The engine is operated in the low-temperature mode while it is not warmed
Removed, seized gear train bushing

up sufficiently. Accordingly, the engine sound becomes a little larger. This
does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode and
Improper gear train backlash

its sound becomes a little larger for up to about 3 seconds. This does not
Clogged, seized injector

indicate abnormality, however.
Dirt caught in injector

tion)
Degree of use
E
Questions

of machine
Condition of Gradually occurred Q Q
abnormal noise Suddenly occurred QQ 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, interference sound is generated around turbo-
w
charger
When engine is cranked, abnormal sound is generated around EGR gas
piping
Check items
When engine is cranked, abnormal sound is generated around cylinder

w w
head
When engine is cranked, beat noise is generated around muffler w
When exhaust manifold is touched immediately after starting engine,
wQ
temperature of some cylinders is low
Color of Blue under light load w
exhaust gas Black Qw Q
Engine does not pick up smoothly and combustion is abnormal w
Abnormal noise is loud when engine is accelerated Q Q QQ
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly qq
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine
qq
speed does not change
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
Correct
Correct
Correct
Correct
Adjust
Remedy
22 PC400, 450-8R
S-16 Vibration is excessive

General causes why vibration is excessive Cause
Misalignment between engine and devices on machine side

q Defective parts (abnormal wear, breakage)
q Misalignment between engine and chassis
q Abnormal combustion
Stuck dynamic valve system (valve, rocker lever)

a If abnormal noise is made and vibration is excessive, carry out troubleshooting for
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
"S-15 Abnormal noise is made", too.

Improper gear train backlash
Broken parts inside damper

Worn camshaft bushing
Questions
Degree of use of
Operated for long period E E E
machine
Condition of Suddenly increased Q Q
vibration Gradually increased Q Q Q
Non-specified fuel is being used Q Q
Metal particles are found when oil filter is drained w w
Check items
a Metal particles are found when oil pan is drained w w

Oil pressure is low at low idle Q Q
Vibration occurs at mid-range speed Q Q
Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w
q
Troubleshooting
Inspect main bearing and connecting rod bearing directly

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
PC400, 450-8R 23
S-17 Air cannot be bled from fuel circuit

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Causes
Defective wiring harness of electric priming pump

q Electric priming pump does not operate.
Improper setting of air bleeding valve (Closed)
Malfunction of electric priming pump switch

q Fuel is not supplied or is supplied very little.
Leaking or clogged fuel piping or air in it

Improper setting of fuel valve (Closed)
Malfunction of electric priming pump

Clogged fuel tank cap breather hole
q Fuel valve or air bleeding valve is not set properly.
Clogged water separator screen

q Air bleeding piping is clogged.
Clogged air bleeding piping

q
Low battery charge level

Fuel return piping is clogged.
Clogged fuel filter

Low fuel level
Questions

Degree of use
of machine
Non-specified fuel is used Q Q
Fuel tank is empty w
Fuel tank cap breather hole is clogged Q w
Check items

When electric Switch lamp does not blink w w Q
priming pump Lamp blinks but pump operation sound is not heard w w
switch is oper- Pump operation sound is heard but fuel does not flow out
ated Q Q w w w Q Q
of hose soon
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and
q
breakage)
Check electric priming pump directly q
Check electric priming system directly (See E-32 in E-mode) q q
Check water separator screen directly q
Check fuel filter for clogging (Failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
24 PC400, 450-8R
PC400, 450-8R 25
©2009 KOMATSU
All Rights Reserved
26
SEN04271-01
PC400, 450-8R
SEN04271-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 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 ............................................................................................................................ 10
PC400, 450-8R 1
SEN04271-01 50 Disassembly and assembly
How to read this manual

(2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for removal or q In "Removal" section, the work procedures, pre-
installation of parts are described as A1, ... X1 cautions and know-how to do the work, and the
etc. and their parts numbers, part names and amount of oil and coolant to be drained are de-
quantities are described in the special tool list. scribed.
q Also the following information is described in the q Common tools that are necessary for removal
special tool list. are described as [1], [2] ••• etc. and their part
1) Necessity numbers, part names and quantities are not de-
t: Special tools that cannot be substituted scribed.
and should always be used q Various symbols used in "Removal" section are
q: Special tools that will be useful if available explained and listed below.
and are substitutable with tools available k : Precautions related to work safety
on the market a : Guidance or precautions for the work
2) Distinction of new and existing special tools [*1]: This mark shows that instructions or precau-
N: Tools newly developed for this model. tions for parts installation work are given in "Installa-
They have a new part number respec- tion" section.
tively. 6 : Amount of oil or coolant to be drained
R: Tools made available by redesign- 4 : Weight of part or component
ingthe existing tools which were devel-

oped for other models. Each of them Installation
has a new part number assigned by q Unless otherwise instructed, installation of parts
setting forward the part number of the is to be done in the reverse order to removal.
existing tool. q Instructions and precautions for parts installation
Blank: Tools already available for other is shown with the mark ([*1], [*2]...) which corre-
models. They can be used without any sponds to the mark in "Removal" section.
modification. q Common tools that are necessary for installation
3) Circle mark Q in sketch column: are described as [1], [2] ••• etc. and their part
q The sketch of the special tool is present-
numbers, part names and quantities are not de-
ed in the section of "Sketches of special scribed.
q Marks shown in the "Installation" section stand
tools".
for the following.
k : Precautions related to work safety
q Part No. of special tools starting with
79*T-***-****:
a : Guidance or precautions for the work
2 : Type of coating material
means that they are not available from
3 : Tightening torque
Komatsu Ltd. (i.e. tools to be made
5 : Amount of oil or coolant to be replenished

locally).

q Various special tools are illustrated for the local
manufacture.
2 PC400, 450-8R
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for disassem- q In "Disassembly" section, the work procedures,
bly and assembly of parts are described as A1, precautions and know-how to do the work, and
••• X1 etc. and their part numbers, part names the amount of oil and coolant to be drained are
and quantities are described in the special tool described.
list. q Common tools that are necessary for disassem-
q Also the following information is described in the bly are described as [1], [2] ••• etc. and their part
special tool list. numbers, part names and quantities are not de-
1) Necessity scribed.
t: Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
q: Special tools that will be useful if available k : Precautions related to work safety
and are substitutable with tools available a : Guidance or precautions for the work
on the market. 6 : Amount of oil or coolant drained
2) Distinction of new and existing special tools

N: Tools newly developed for this model. Assembly
They have a new part number respec- q In "Assembly" section, the work procedures, pre-
tively. cautions and know-how to do the work, and the
R: Tools made available by redesigning amount of oil and coolant to be replenished are
the existing tools which were devel- described.
oped for other models. Each of them q Common tools that are necessary for assembly
has a new part number assigned by are described as [1], [2] ••• etc. and their part
setting forward the part number of the numbers, part names and quantities are not de-
existing tool. scribed.
Blank:Tools already available for other q The meanings of the symbols used in "Assem-
models. They can be used without any bly" section are as follows.
modification. k : Precautions related to work safety
3) Circle mark Q in sketch column: a : Guidance or precautions for the work

2 : Type of coating material
3 : Tightening torque
q The sketch of the special tool is present-
5 : Amount of oil or coolant to be replenished

ed in the section of "Sketches of special
tools".
q Part No. of special tools starting with
79*T-***-****: Sketches of special tools
means that they are not available from q Various special tools are illustrated for the local
Komatsu Ltd. (i.e. tools to be made manufacture.
locally).
PC400, 450-8R 3
Coating materials list

(Rev. 2009. 02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassem-
bly 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
q Use to prevent rubber gaskets, rubber cushions, and
LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
q Use for plastic (except polyethylene, polypropylene,
Polyethyl-
20 g tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050 ene con-
(2pcs.) and non-metal parts which require immediate and
tainer
strong adhesion.
Polyethyl-
q Features: Resistance to heat and chemicals.
LT-2 790-129-9030 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Used to stick and seal metal, glass, and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs.
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Quick-setting adhesive.
Polyethyl-
Three- q Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g ene con-
Bond 1735 q Used mainly to stick metals, rubbers, plastics, and
tainer
woods.
q Quick-setting adhesive.
Polyethyl-
Aron-alpha q Quick-setting type.
790-129-9130 2g ene con-
201 (max. strength is obtained after 30 minutes)
tainer
q Used mainly to stick rubbers, plastics, and metals.
Polyethyl-
Loctite q Features: Resistance to heat and chemicals.
79A-129-9110 50 cc ene con-
648-50 q Used for fitted portions used at high temperatures.
tainer
q Use to seal various threaded portions, pipejoints, and
Polyethyl-
flanges.
LG-5 790-129-9080 1 kg ene con-
q Used to seal tapered plugs, elbows, and nipples of hy-
tainer
draulic piping.
q Features: Silicon-based heat and cold-resistant seal-
ant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
q Use to seal oil pan, final drive case, etc.
q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake mani thermostat
old, oil pan, thermostat housing, etc.
Gasket sealant
LG-8 q Features: Silicon-based, heat and cold-resistant, vi-

ThreeBond 419-15-18131 100 g Tube bration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top seal
LG-9
which does not need to be clamped, water resistance
ThreeBond 790-129-9310 200 g Tube
of the clearance at the welded area, etc.
1206D
q Can be coated with paint.
LG-10 q Used as lubricant/sealant when the radiator hoses are
ThreeBond 790-129-9320 200 g Tube inserted.
1206E q Can be coated with paint.
LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steering
1121 case etc.
ThreeBond
790-129-9090 100 g Tube q Gasket sealant used to repair engine.
1211
4 PC400, 450-8R
Cate- Komatsu
gory code
q Use to prevent scuffing and seizure of press-fitted por-
Molybdenum disulfide lubricant
LM-P 09940-00040 200 g Tube tions, shrink-fitted portions, and threaded portions.
q Use to lubricate linkages, bearings, etc.
q Spray type
q Thin molybdenum disulphide films are made on metal
surfaces to prevent the metals from scuffing each oth-
― 09995-00250 190 g Can
er.
q Applicable for the propeller shaft splines, needle bear-
ings, pins and bolts of various links, etc.
Seizure prevention
q
compound
Feature: Seizure and galling prevention compound

LC-G
with metallic super-fine-grain, etc.
NEVER-SE ― ― Can
q Use for the mounting bolt in the high temperature area
EZ
of the exhaust manifold and the turbocharger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
q Feature: Lithium grease with extreme pressure lubri-
G0-LI (*) SYGA-160CN
Various Various cation performance.
*: For cold LI
q General purpose type.
district SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
q Used for parts under heavy load.
Molybde-
Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type
q Do not apply grease to rolling bearings like swing circle
fide grease SYG2-400M-A 400 g × 20 container
bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can
q Use this grease to work equipment pins only when in-
(G2-M)
stalling them, but do not use it afterward.
Hyper-
SYG2-400T-A
White
SYG2-16CNT
Grease 400 g Bellows-type q Seizure resistance, heat resistance and water resis-
SYG0-400T-A
Grease
G2-T, container tance higher than molybdenum disulfide grease.

(*)
G0-T (*) 16 Kg Can q Not conspicuous on machine since color is white.
SYG0-16CNT
*: For cold
(*)
district
Biogrease
G2-B SYG2-400B
G2-BT (*) SYGA-16CNB
400 g Bellows-type q Since this grease is biodegradable in short period, it
*: For use
SYG2-400BT
container has less impact on microorganisms, animals, and
at high tem- (*) 16 Kg Can plants.
perature SYGA-16CNB
and under T (*)
high load
q Feature: Silicone grease with wide usable temperature
G2-S range, high resistance to thermal-oxidative degrada-
ThreeBond ― 200 g Tube tion and performance to prevent deterioration of rub-
1855 ber and plastic parts.
q Use for oil seals of the transmission, etc.
q Feature: Urea (organic system) grease with heat resis-
G2-U-S tance and long life can be packed into the confined
ENS 427-12-11871 2 kg Can space and left intact until next overhaul.
grease q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
PC400, 450-8R 5
Cate- Komatsu
gory code
SUNSTAR
PAINT q Used as primer for cab side.
Glass con-
PRIMER 20 ml (Using limit: 4 months after date of manufac-
tainer
580 ture)
SUPER
417-926-3910
SUNSTAR
GLASS q Used as primer for glass side.
Glass con-
PRIMER 20 ml (Using limit: 4 months after date of manufac-
Adhesive for cab glass

tainer
580 ture)
SUPER
SUNSTAR
Primer
q Used as primer for painted surface on cab side.

PAINT Glass con-
22M-54-27230 20 ml (Using limit: 4 months after date of manufac-
PRIMER tainer
ture)
435-95
q Used as primer for black ceramic-coated sur-
SUNSTAR
face on glass side and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Using limit: 4 months after date of manufac-
435-41
ture)
SUNSTAR
q Used as primer for sash (Almite).
SASH Glass con-
22M-54-27250 20 ml (Using limit: 4 months after date of manufac-
PRIMER tainer
ture)
GP-402
SUNSTAR
q “S” is used for high-temperature season and
PEN-
Polyethyl- “W” for low-temperature season as adhesive for
GUINE
417-926-3910 320 ml ene con- glass.
SEAL 580
tainer (Using limit: 4 months after date of manufac-
SUPER “
ture)
S" or “ W"
Adhesive
Sika Japan, Polyethyl- q Used as adhesive for glass.

Sikaflex 20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manufac-
256HV tainer ture)
SUNSTAR
PEN- Ecocart q Used as adhesive for glass.
Adhesive for cab glass
GUINE 22M-54-27210 320 ml (Special con- (Using limit: 6 months after date of manufac-
SUPER tainer) ture)
560
SUNSTAR
PEN- Polyethyl- q Used to seal joints of glass parts.
GUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manufac-
SEALNo. tainer ture)
2505
Caulking material
SEKISUI Polyethyl- q Use to seal front window.

SILICONE 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manufac-
SEALANT tainer ture)
GE
TOSHIBA q Used to seal joint of glasses. Translucent white
SILI- seal.
22M-54-27220 333 ml Cartridge
CONES (Using limit: 12 months after date of manufac-
TOSSEAL ture)
381
6 PC400, 450-8R
Special tools list

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity:
t ………… Cannot be substituted, must always be installed (used)
q ………… Extremely useful if available or can be substituted with commercially available part
a New/Redesign:
N : .............Tools with new part numbers, newly developed for this model
R : .............Tools with upgraded part numbers, remodeled from items already available for other models
Blank : .............Tools already available for other models, can be used without any modification
a Tools marked with Q in the Sketch column are tools introduced 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 2 01010-81080 Bolt t 2 Removal of fuel supply pump
3 01643-31032 Washer t 2
4 795-931-1100 Seal puller assembly q 1 Removal of rear oil seal
5 795-931-1210 Sleeve jig tool t 1
Rear oil seal A 6 795-931-1220 Sleeve jig tool t 1
Press fitting of rear oil seal
7 01050-31645 Bolt t 3
8 01050-31625 Bolt t 3
Angle tightening of bolt 9 790-331-1110 Wrench q 1
Engine valve clear- Adjustment of engine valve
10 795-125-1360 Clearance gauge q 1
ance clearance
Removal, installation of engine
B 796T-601-1110 Stopper t 1 Q
Engine and hydraulic mounting bolt
pump assembly 796-460-1210 Oil stopper q 1
C Stopping of oil
796-770-1320 Adapter q 1
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 q Plate 1
Swing motor and 4 Press fitting of oil seal
790-101-5421 q Grip 1
swing machinery D
01010-51240 q Bolt 1
assembly 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 q Wrench 1 Removal, installation of round
1
796-427-1140 q Pin 3 nut
01314-20612 q Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
791-122-1130 Plate q 1
Final drive assembly E
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
PC400, 450-8R 7
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 791-430-3230 Installer t 1
Carrier roller assembly F
2 791-601-1000 Oil pump t 1
1 791-630-1780 Installer t 1
Track roller assembly G
2 791-601-1000 Oil pump t 1
1 791-575-1520 Installer t 1
Idler assembly H
2 791-601-1000 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 ton})
Recoil spring assem-
J 790-101-1102 Pump t 1
bly
790-201-1660 q Plate 1
2 Installation of dust seal
790-101-5021 q Grip 1
01010-50816 q Bolt 1
791-650-3000 Remover and installer t 1
Cylinder
Track shoe assembly K 790-101-1300 t 1 Pulling out of master pin
(980 kN {100 ton})
790-101-1102 Pump t 1
796-946-1310 Guide f21.8
1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide f20.9
1 1
(For 723-46-44100)
796-946-2210 Guide f20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide f21.6
1
(For 723-46-42800)
2
Control valve assem- 796-946-2120 Guide Replacement of pressure com-
L 1
bly (For 723-46-44100) pensation 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 q Block 1
790-101-2520 q Screw 1
791-112-1180 q Nut 1
Center swivel joint Disassembly, assembly of cen-
1 790-101-2540 q Washer 1
assembly M ter swivel joint assembly
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q Adapter 2
2 796T-416-1010 Push tool t 1 N Q
Travel PPC valve 3 796T-416-1030 Push tool t 1 N Q Disassembly and assembly of
assembly travel PPC valve assembly
4 796T-416-1020 Push tool t 1 N Q
8 PC400, 450-8R
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 q Push tool
N 790-201-1851 1
assembly (For bucket)
q Push tool
790-201-1861 1
5 (For boom) Press fitting of bushing
q Push tool
790-201-1871 1
(For arm) f120
790-101-5021 q Grip 1
01010-50816 q Bolt 1
790-101-5021 q Grip 1
01010-50816 q Bolt 1
6 Press fitting of dust seal
790-201-1660 q Plate (For bucket) 1
790-201-1670 q Plate (For boom) 1
790-201-1680 q Plate (For arm) 1
796-670-1100 Remover q 1
796-670-1110 q Sleeve 1
796-670-1120 q Plate 1
796-670-1130 q Screw 1
Work equipment 796-870-1110 q Adapter 1
P Removal of foot pin
assembly 01643-33080 q Washer 1
01803-13034 q Nut 1
Puller (490 kN {50 ton},
790-101-4000 q 1
long)
790-101-1102 Pump (294 kN {30 ton}) q 1
Operator cab glass 2 793-498-1210 Lifter (Suction cup) t 2 Installation of operator cab
X
(stuck glass) 3 20Y-54-13180 Stopper rubber t 2 glass (stuck glass)
Commercially
Impact wrench q 1
available
Counterweight assem- Removal and installation of
― Socket wrench
bly Commercially counterweight assembly
(Width across flats: 65 q 1
available
mm)
PC400, 450-8R 9

B. Stopper
10 PC400, 450-8R
D7. Push tool
E2. Push tool
PC400, 450-8R 11
M2. Push tool
M3. Push tool
12 PC400, 450-8R
M4. Push tool
PC400, 450-8R 13
©2009 KOMATSU
All Rights Reserved
14
SEN04272-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 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 ................................................................................................ 13
Removal and installation of cylinder head assembly .................................................................................... 16
Removal and installation of radiator assembly ............................................................................................. 25
Removal and installation of hydraulic oil cooler assembly ............................................................................ 27
Removal and installation of aftercooler assembly......................................................................................... 29
Removal and installation of engine and hydraulic oil pump assembly .......................................................... 30
PC400, 450-8R 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
Symbol
Sketch
pipe clamp (13) and 2 boots (13A). [*1]
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 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
Removal
k Disconnect the negative (–) terminal of battery.
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
the bracket mounting bolts, remove air condi-
tioner compressor assembly (4) and deposit 12. Disconnect inlet tube (15) of the fuel supply
them on the floor cover. pump. [*3]
2 PC400, 450-8R
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. Setting the tools
1) Insert the bar into the fan pulley round hole
(a) and rotate the crankshaft normally.
a Rotate by tightening the fan belt or
pressing hard on the mid section of
the V-belt.
15. Remove cover (20) on the side of timing gear

case.
PC400, 450-8R 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 (a) between the damper 2- installed next. [*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, 450-8R
Installation
a Carry out installation in the reverse order to
removal.
[*1]
Tighten clamp (13) with the hand first, and then
tighten it permanently.
3 Clamp mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*2]
Install high-pressure tube (14) by tightening by
hand, then tighten it permanently.
3 Sleeve nut of the high-pressure tube:
Common rail side:
39.2 – 58.8 Nm {4 – 6 kgm}
Pump side: 39.2 – 49 Nm {4 – 5 kgm}
a Face the common rail side slit of the splash
prevention cover downward and the supply
pump side slit toward the cylinder block.
[*3]
3 Joint bolt of tube (15):
25.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
a Match the key and keyway to install.
[*5]
3 Joint bolt of pump side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
2 Mounting bolt: Gasket sealant (LT-2)
q Fuel leak check

Refer to the paragraph on the "Checking fuel
circuit for leakage” in Testing and adjusting,
and check the fuel system for any leakage
accordingly.
q Air bleeding
Refer to the paragraph on the "Bleeding air
from fuel circuit" in Testing and adjusting, and
bleed the air accordingly.
PC400, 450-8R 5
Removal and installation of fuel 6. Remove clamp (4) and remove air intake tube
injector assembly 1 (5). [*1]
Removal
1. Drain coolant.
6 Coolant: Approx. 36 l
2. Drain hydraulic oil.

6 Hydraulic oil: Approx. 248 l
3. Close the fuel stopper valve on the fuel tank.
4. Remove connector P24, overflow tube (1) and

sub-tank (2). 7. Remove the clamp and disconnect hose (9)
between the radiator and the engine at the
5. Remove the mounting bolt and then hoist the radiator side. [*2]
engine hood assembly (3) to remove. 8. Remove covers (6), (7), and fan guard (8).
4 Engine hood: 200 kg
9. Remove oil filter (10). (Leave the tube unre-

moved)
10. Remove fuel pre-filter (11).

(after disconnecting the hose, put it at the left
side of the engine)
6 PC400, 450-8R
11. When manual priming pump (12) is installed,

remove priming pump (12).
a After disconnecting the hoses, let each
hose put on the left-hand side of the
engine.
12. Remove fuel main filter (13).
(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine. [*3]
13. Disconnect the terminal of intake air heater

harness (14).
a Disconnect the clamp.
14. Remove the air intake connector (15).
16. Remove clamp (23), bolts (24) and bracket (25)

to remove the housing complex (diffuser) (26).
15. Disconnect TIM (boost temperature) (18), PIM

(boost pressure sensor) (20), PAMB (atmo-
spheric sensor) (21), connector (22), and wir-
ing clamps (19).
a Remove harness clamps. 17. Disconnect injector harness connectors (27) (at 6
a Place removed parts together under the places), remove the clamp and shift the harness
engine. [*4] to the lower left-hand side of the engine.
a For how to remove the connector, see the
“Removal and installation of cylinder head
assembly”.
18. Remove clamps (28) and boots (29).
PC400, 450-8R 7
19. Remove the clamp and 6 high-pressure injec- 22. Removal of rocker arm assembly (35).
tion tubes (30). [*5] [*6] 1) Loosen locknut (36) and then loosen
adjustment screw (37).
2) Remove mounting bolt (38) and then
rocker arm and shaft assembly (35).
20. Remove head cover (31). [*7]
23. Remove holder mounting bolt (40) of injector

(39) and then remove injector (39) along with
holder (41). [*10]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
21. Removal of injector harness.

1) Fully loosen 2 capture nuts (33) on the
head of injector (32). [*8]
a Loosen nuts alternately.
2) Loosen bolt (34) of harness fixing holder.
[*9]
8 PC400, 450-8R
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 (9): 3 Sleeve nut (on both sides):
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
them permanently.
3 Mounting bolt:
Fuel filter joint bolt:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Install clamps (78), (79), (80) and (81).
[*4]
4) Install 6 each splash prevention covers
Keep the harness assembly and other harnesses 10 (82) and (83).
mm and above away from the high-pressure tube. a Direct the slit on the injector side
downward and that on the common
[*5] rail side toward the cylinder block.
k Don't correct high-pressure tube by bend- 5) Install bracket (84).
ing it for re-use. 3 Mounting bolt:
k Always use genuine clamp for fixing high- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
pressure pipe. Strictly observe the tighten- 6) Install clamps (78), (79), (80) and (81).
ing torque requirements. 3 Mounting bolt:
k Keep the harness assembly and other har- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
nesses 10 mm and above away from the
high-pressure tube.
[*6]
Check the following matters before installing high-
pressure pipe. If there is any abnormality, replace
the high-pressure tube to prevent possible fuel
leakage.
q Check the taper seal portion (between the tip

of section (a) and 2 mm from the end) of the
joint section for any vertical slit (b) and/or dent
(c) visually recognizable.
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, 450-8R 9
2) Install gasket (91) and O-rings (92) and (93) to

injector (85).
2 O-ring: Engine oil (EO30-DH)
[*7]
3 Head cover mounting bolt
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3) Insert holder (87) to injector (86). While holding
[*8] them in this state, insert inlet connector (90) to
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm} the locker housing toward the high-pressure
pipe insertion hole.
[*9]
Tighten the mounting bolt of harness holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
[*10]
Check that the inside of the injector sleeve is free
from dirt.
1) Loosen the mounting bolt of common rail (85).
4) Fit the ball washer to bolt (88) and tighten

holder (87) temporarily.
2 Spherical part of washer:
Engine oil (EO30-DH)
5) Locate high-pressure sleeve (89) to inlet con-
nector (90) and then tighten them temporarily.
a Tighten the common rail side sleeve nut
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, 450-8R
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.
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, 450-8R 11
Removal and installation of 6. Remove fan belt (7) and the air compressor
engine front seal 1 belt (8).
7. Sling the damper and pulley assembly (9) and
then remove it by loosening 6 mounting bolts.
4
Removal
Damper and pulley assembly: 25 kg
1. See the paragraphs for the “Removal and
installation of radiator”, “Removal and installa- 8. Remove front seal.
tion of hydraulic oil cooler”, and “Removal and
installation of aftercooler” to remove the radia-
tor, hydraulic oil cooler and the aftercooler.
2. Remove covers (1) and fan guard (2).
Installation
q Carry out installation in the reverse order to
removal.
3. Loosen the air compressor assembly mounting
bolts and loosen adjustment nuts (3). Using the push tool (outside diameter 120 mm),
4. Loosen alternator assembly adjustment nuts press fit front oil seal to the cover.
(4) and adjustment bolt guide (5). a Oil seal press-fit margin (a): 16 (+1/0) mm
2 Oil seal lip (50 – 80% of void lip space):
Grease (G2-LI)
5. Remove fan (6).
12 PC400, 450-8R
Removal and installation of 5. Removal of rear seal

engine rear seal 1 Removal of standard seal
Hitch the end of tool A4 to the metal ring of
seal (1) and pull out the seal with impacts of
Special tools slide hammer [1].
a Before pulling out the seal, drive it in a lit-
Necessity
Symbol
Sketch
tle to loosen adhesion between the seal
Q’ty
N/R
Part number Part name and housing (2) for the ease of removal.
a Do not use a drill, etc. since chips may
Seal puller enter the engine.
4 795-931-1100 q 1
assembly
5 795-931-1210 Sleeve jig t 1
A
6 795-931-1220 Sleeve jig t 1
7 01050-31645 Bolt t 3
8 01050-31625 Bolt t 3
Removal
1. Remove hydraulic pump assembly by reading
the paragraph for the “Removal and installation
of hydraulic pump assembly.”
2. Remove the damper.

Removal of sleeved seal
3. Sling the flywheel (2) by leaving a flywheel 1) Hitch the end of tool A4 to the metal ring
mounting bolt (1) unremoved. of seal (1) and pull out the seal with
impacts of slide hammer [1].
4. Sling the flywheel (2) to remove. a Before pulling out the seal, drive it in
4 Flywheel assembly: 60 kg a little to loosen adhesion between
k
the seal and housing for the ease of
Since the sling [1] is held slanted when removal.
the flywheel is lifted, care should be 2) Cut and remove sleeve (3) with a chisel
taken for the swinging of sling when and a hammer.
the flywheel assembly (2) is released. a Take care not to damage crankshaft
(4).
a Remove all the chips, if any.
PC400, 450-8R 13
Installation
removal.
Installation of rear seal

a Check the Teflon seal (Laydown lip seal) for
the wear of the shaft and install "Standard seal"
or “Sleeved seal”.
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a The left one in the following figure is the stan-
dard seal and the right one is the sleeved seal.
2) Hold the metal ring of seal (1) with both

hands and push it in firmly by applying
force equally.
Procedure for installing standard seal 3) After pushing in the seal, remove plastic
a Before installing the seal, check that the end inner cylinder (3).
corners and lip sliding surfaces of crankshaft a When removing the inner cylinder,
(4) are free from housing flaw, burr, sharp edge take care not to damage the seal lip.
and rust.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip (a). Wipe off oil
from the shaft.
a Never remove plastic inner cylinder (3) of the
standard spare seal before installing the seal.
1) Set the larger inside diameter side (b) of
plastic inner cylinder (3) to the end of
crankshaft (4).
a Take care not to mistake the direction
of the plastic inner cylinder.
4) Tighten the bolts (A7 and A8) evenly to

press fit seal (1) until the end of tool A5
reaches the end of crankshaft (4).
a First, tighten tool A5 until bolt A7 (45
mm under head) stops, then tighten
bolt A8 (25 mm under head).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
14 PC400, 450-8R
a After press fitting the seal, remove the 2) Set the sleeve of the seal to the end of the
red sealant layer from its periphery. crankshaft, and then tighten the bolt A7
0
evenly to press fit sleeve and seal assem-
bly (2) until the end of tool A6 reaches the
end of crankshaft (4).
Procedure for installing sleeved seal

a Before installing the seal, make sure that the
end corners and lip sliding surfaces of crank- 3) Remove tool A6 and install tool A5.
shaft are free from housing flaws, burrs, sharp 4) Tighten the bolts A8 evenly to press fit
edges and rusts, etc. seal assembly (2) until the end of tool A5
a When installing the seal, do not apply oil or reaches the end of crankshaft (4).
grease to between shaft, sleeve (1), and seal a After press fitting the seal, remove the
lip (a). Wipe off oil from the shaft. red sealant layer from its periphery.
a Handle the seal and sleeve as an assembly
and don't separate them from each other.
1) Set the sleeve seal assembly (2) to tool A6.

2 Sleeve inner cylinder surface:
Gasket sealant (LG-7)
PC400, 450-8R 15
Removal and installation of 6. Remove clamp (4) and remove air intake tube
cylinder head assembly 1 (5). [*1]
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
A9 790-331-1110 Wrench q 1
A10 795-125-1360 Clearance gauge q 1
Removal
1. Drain coolant.
2. Drain hydraulic oil. 7. Remove the clamp and disconnect hose (9)
6
between the radiator and the engine at the
Hydraulic oil: Approx. 248 l
radiator side. [*2]
3. Close the fuel stopper valve on the fuel tank.
8. Remove covers (6), (7), and fan guard (8).
4. Disconnect connector P24 and overflow tube
(1) and remove the sub-tank (2).
5. Remove the mounting bolt and then hoist the

engine hood assembly (3) to remove.
9. Remove the exhaust pipe cover (10) and the

muffler cover (11).
16 PC400, 450-8R
10. Remove clamp (12) and 2 clamps (13) of muf- 15. Disconnect the terminal of intake air heater
fler. Shift the muffler (14) to remove the joint harness (19).
tube (15) and the muffler (14). a Disconnect the clamp, too.
11. Remove oil filter (80). (Leave the tube unre-

moved) 17. Disconnect TIM (boost temperature sensor)
(23), PIM (boost pressure sensor) (25), PAMB
(atmospheric sensor) (26), connector (27), and
wiring clamps (24).
a Remove clamps.
a Place removed parts together under the
engine. [*4]
12. Remove the fuel pre-filter (16).

(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
13. When manual priming pump (17) is installed,
remove priming pump (17).
(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
14. Remove the fuel main filter (18).
(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine.) [*3]
PC400, 450-8R 17
18. Remove clamp (28), bolt (29) and brackets 21. Remove clamp (34) and boots (35) to remove
(30) to remove the housing complex (diffuser) 6 high-pressure injection tubes (36). [*4] [*8]
(31).
19. Remove brackets (behind the front hanger)
(32).
20. Disconnect injector harness (33) and move it

to the lower left-hand side of the engine.
22. Remove the housing (41) by removing mount-

ing bolts. [*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).
18 PC400, 450-8R
23. Sling the air intake manifold assembly (42), 25. Remove exhaust manifold heat insulation covers
remove 24 mounting bolts to remove the (47).
assembly.
4 Air intake manifold: 25 kg
26. Disconnect turbocharger lubrication inlet tube

(48) and disconnect the drain tube (49). [*6]
24. Remove hose (43).
27. Sling the turbocharger and exhaust manifold

assembly (50), and remove the mounting bolts.
[*7]
28. Remove turbocharger and exhaust manifold

assembly by hoisting.
4 Turbocharger and exhaust manifold
assembly: 40 kg
PC400, 450-8R 19
29. Remove spill tube (51). [*9] 33. Removal of rocker arm assembly (57) [*13]
1) Loosen locknut (58) and then loosen
30. Remove air vent tube (52). [*10] adjustment screw (59).
2) Remove mounting bolt (60) and then
rocker arm and shaft assembly (57).
31. Remove head cover (53). [*11]
34. Remove 12 push rods (61).
32. Removal of injector harness [*12]

1) Fully loosen two capture nuts (55) on the
head of injector (54). 35. Remove holder mounting bolt (63) of injector
a Loosen nuts alternately. (62) and then remove injector along with
2) Loosen bolt (56) of harness fixing holder. holder (64). [*14]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
20 PC400, 450-8R
36. Remove 12 crossheads (65). [*15] 38. Remove rocker housing (71). [*16]
37. Removal of injector harness connector 39. Removal of cylinder head assembly [*17]
1) Remove mounting bolt (67) of harness 1) Remove each set of 7 mounting bolts (74)
connector (66). of cylinder head assembly (73).
2) Remove holder (69) from the harness. 2) Using eyebolt [1], lift and remove cylinder
head assembly (73).
4 Cylinder head assembly: 20 kg
3) Remove each head gasket.
3) Remove harness connector (70) by push-

ing it outward from inside of rocker hous-
ing (71).
4) Remove O-ring (72) from the rocker hous-
ing.
PC400, 450-8R 21
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}
[*8]
[*4] a For details on and how to install the high-pres-
Keep the harness assembly and other harnesses s u r e t u b e c o v e r, s e e P a r a g r a p h [ * 5 ] i n
10 mm and above away from the high-pressure "Removal and installation of fuel injector
tube. assembly."
[*5] High-pressure tube installation instructions

Tighten the air intake manifold assembly mounting a Don't correct high-pressure tube by bending it
bolts in the order given below. for re-use.
3 Intake manifold assembly: 1) Tighten high-pressure tube permanently.
59 – 74 Nm {6 – 7.5 kgm} 3 Sleeve nut:
39.2 – 49 Nm {4 – 5 kgm}
2) Temporarily tighten high-pressure clamp and
brackets all by hand.
3) Tighten high-pressure tube clamp perma-
nently.
3 Clamp nut:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Tighten bracket permanently.
5) Install cover.
a Direct the slit to the side of cylinder head.
6) Temporarily install gate-type bracket and cover
(also working as clamp).
7) Tighten the cover permanently.
3 Cover mounting bolt:
[*6] 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 Lubrication tube sleeve nut: 8) Tighten the gate-type bracket permanently.
40 – 44 Nm {4.1 – 4.5 kgm}
[*9]
[*7] 3 Spill tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Tighten the exhaust manifold assembly mounting
bolts in the order given below, then tighten other [*10]
bolts. 3 Air vent tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Exhaust manifold assembly mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm} [*11]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*12]
a Tighten the capture nuts alternately.
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
22 PC400, 450-8R
[*13] [*17]
1) Loosen locknut, then install rocker arm and a Clean the bottom face, block top face and liner
rocker shaft assembly. with dry cloth or soaked with a solvent.
3 Rocker shaft mounting bolt: a Replace a bolt having 5 punch marks to the
58.8 – 73.5 Nm {6 – 7.5 kgm} bolt head.
2) Remove the cover and adjust the valve clear- a Tighten the bolt with hand and screw in to the
ance. block by turning the bolt at least 2 rounds.
Pointer is located under the cover. 2 Bolt threaded portion and under side of
q Valve clearance the bolt head:
Intake : 0.33 mm LM-P or engine oil (EO30-DH)
Exhaust : 0.71 mm a Tighten the cylinder head mounting bolts in the
a See the paragraph of “Adjusting valve clear- order indicated in the figure.
ance” in the part for Testing and adjusting for 3 Cylinder head mounting bolt 1 – 6:
the valve clearance instructions. 1st time: 98.1 ± 9.8 Nm {10 ± 1 kgm}
3 Rocker arm locknut: 2nd time: 166.6 – 176.4 Nm {17 – 18
58.8 – 73.5 Nm {6 – 7.5 kgm} kgm}
3rd time: Tighten bolt to 90 to 120°
[*14] (target 120°) using tool A9.
For the mounting instructions of injector and holder,
see the paragraph for the "Removal and installation
of fuel injector assembly."
[*15]
a Amply apply engine oil (EO30-DH) to cross-
head guide and crosshead top face.
a Adjust the crosshead according to the follow-
ing procedure.
1) Loosen the locknut and return the adjust-
ment screw.
2) Holding the top of the crosshead lightly,
tighten the adjustment screw while keep-
ing the crosshead in contact with the valve
stem.
3) After the adjustment screw touches the
valve stem, tighten it further by 20°.
4) Tighten the locknut at this position.
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
[*16]
3 Rocker housing mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
PC400, 450-8R 23
a When not using tool A9

After applying a paint marking to the cylinder
head and bolt, tighten the bolt by 90° to 120°
(target 120°).
a After tightening bolts 1 – 6, tighten auxiliary
bolt 7.
3 Cylinder head mounting auxiliary bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
a After tightening the bolt, punch a mark on its

head.
a When using a new bolt, do not punch a mark
on its head.
q Feed coolant
coolant level.
24 PC400, 450-8R
Removal and installation of 5. Remove the clamp and hoses (6), (7), (8) and
radiator assembly 1 (9) between the radiator and the engine. [*1]
6. Remove radiator front covers (10), (10A).

Removal
1. Remove covers (1) and (2).
7. Remove undercover.
2. Drain coolant. 9. Disconnect the lower hose (12).
3. Disconnect connector (P24) and overflow tube
10. Remove 2 upper mounting bolts (13).
PC400, 450-8R 25
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.
[*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}
26 PC400, 450-8R

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.
5. Remove covers (5), (6) and (6A).
2. Remove cover under the hydraulic oil tank

drain plug. Remove the hydraulic oil tank drain
hose plug to drain hydraulic oil.
a Open the hydraulic oil tank cap before 6. Remove tube (8).
draining to release the tank inner pres- a Remove drain plug (7) and then remove
sure. Then drain oil from the cooler hose. fuel tube (8) after draining oil inside.
3. Disconnect connector P24 and overflow tube

PC400, 450-8R 27
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

(13).
4 Hydraulic oil cooler assembly: 45 kg
28 PC400, 450-8R
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 aftercooler assembly with nylon
Removal slings, etc. before the hose is completely
1. Open the radiator front cover. extracted. Withdraw the hose and pull out the
2. Remove undercover (1). aftercooler assembly sideway to remove.
4 Aftercooler assembly: 25 kg
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, 450-8R 29
Removal and installation of 3. Close the fuel stopper valve on the fuel tank.
engine and hydraulic oil pump
4. Disconnect connector (P24) and overflow tube
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 Q
796-460-1210 Oil stopper q 1
C
796-770-1320 Adapter q 1
Removal
k Disconnect the negative (–) terminal of bat-
tery.
k Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
a Take care not to mistake installation position of
each piping by attaching tags, etc.
1. Drain coolant.
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. Remove floor cover (4) on the control valve.

a Remove cover (4) to remove the following
covers (5) through (8).
30 PC400, 450-8R
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 2 sound absorbing covers (20), 2 cov-

ers (21) and fan guard (22).
9. Remove undercovers (13) and (14).
PC400, 450-8R 31
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 (27) 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.
32 PC400, 450-8R
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 clamps (38) at 2 locations. 27. Disconnect the car heater hose (43).
23. Remove grounding T11 (39).
24. Disconnect oil level sensor connector P44
(40).
PC400, 450-8R 33
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)
34 PC400, 450-8R
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, 450-8R 35
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
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.
q Air bleeding
Refer to the paragraph on the "Bleeding air
from various parts" in Testing and adjusting.
36 PC400, 450-8R
PC400, 450-8R 37
SEN04272-01

© 2010 KOMATSU
All Rights Reserved
38
SEN04273-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Power train
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 3
Removal and installation of swing motor and swing machinery assembly ....................................................11
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 12
Removal and installation of swing circle assembly ....................................................................................... 19
PC400, 450-8R 1
Removal and installation of final 4. Remove the 24 mounting bolts and lift off the
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.
Installation
removal.
[*1]
3. Disconnect drain hose (2), travel speed selec- 3 Mounting bolt:
tor hose (3), and motor hoses (4) and (5). 490 – 608 Nm {50 – 62 kgm}
a Remove the nipples, too.
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
2 PC400, 450-8R
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: Approx. 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, 450-8R 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

according to the following procedure.
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) from No. 2 carrier 1) Remove lock plate (23) from locknut (24).
assembly (15).
4 PC400, 450-8R
2) Using tool E1, remove locknut. ii) Remove floating seal (27) from hub
(32).
9. Hub assembly
1) Using eyebolts [3], remove hub assembly iii) Remove bearings (28) and (29).
(25) from the travel motor.
3) Remove floating seal (30) from travel

2) Disassemble hub assembly (25) accord- motor (31).
i) Remove bearing (26) from hub (32).
PC400, 450-8R 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).
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, 450-8R
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 E1, 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 t}
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 t}
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, 450-8R 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) to No. 2 carrier
assembly (15).
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, 450-8R
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
assembly, 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
top and bottom thrust washers (8)
an d ( 11) , an d th en set t he ge ar
assembly to carrier (7). 2) Install No. 1 carrier assembly (4).
PC400, 450-8R 9
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).
8. Spacer
Install spacer (2).
9. Cover
Using eyebolts [2], install cover (1) and tighten
the mounting bolts.
2 Cover mounting face:

3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
q Refilling with oil

a Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely
cold district) through the oil filler.
5 Final drive case: Approx. 11 l
a After installing the final drive assembly to
the chassis, check the oil level again at
the specified position.
10 PC400, 450-8R
Removal and installation of swing 3. Lift and remove swing motor and swing
motor and swing machinery machinery assembly (6).
a When lifting the swing motor and swing
assembly 1 machinery assembly for removal, do so
slowly so that the hoses and other parts
Removal will not be damaged.
k Release the residual pressure in the a Take good care, when lifting the assembly,
hydraulic circuit. Refer to the “Releasing until the spigot joint portion is pulled out.
residual pressure from hydraulic circuit”
4
section in the Testing and adjusting chap- Swing motor and swing machinery
ter of this manual.
k
assembly: 550 kg
Lower the work equipment to the ground
for oil filler cap on the fuel tank to release
the residual pressure inside the tank and
move the work equipment lock lever to the
LOCK position.
1. Disconnect 5 swing motor hoses (1) through

(5).
q (1): Between swing motor and control
valve (MA port)
q (2): Between swing motor and control
valve (MB port)
q (3): Suction hose (S port)
q (4): Drain hose (T port)
q (5): Swing brake releasing pilot hose (B
port)
Installation
q Install in reverse order of removal.
[*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
2. Disconnect the swing motor and swing Refer to the “Bleeding air from various parts” in
machinery assembly (6), using forcing screw the Testing and adjusting chapter of this man-
[1] after removing the mounting bolts. [*1] ual.
PC400, 450-8R 11
Disassembly and assembly of 3. No. 1 sun gear

swing motor and swing Remove No. 1 sun gear (2).
machinery assembly 1
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 4. No. 1 carrier assembly
790-101-5421 • Grip 1
1) Remove No. 1 carrier assembly (3).
01010-51240 • Bolt 1
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: Approx. 21 l
2. Swing motor assembly

1) Set the swing motor and swing machinery 2) Disassemble the No. 1 carrier assembly
assembly on block [1]. according to the following procedure.
2) Remove 10 mounting bolts and lift off Remove snap ring (4), and then remove
swing motor assembly (1). shaft (5), gear (6), bearing (7), thrust
washer (8), and plate (9).
4 Swing motor assembly: 115 kg
12 PC400, 450-8R
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 mounting bolt (12) of No. 2 carrier
assembly (13).
9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of
cover assembly (22).
PC400, 450-8R 13
2) Turn over case and pinion assembly (24) 10. 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
3) Disassemble the pinion shaft assembly damage. Coat their sliding surfaces with
according to the following procedure. engine oil before installing.
i) Using the push tool, remove cover
assembly (22) and bearing (26) from 1. Bearing
shaft (27). Using push tool D3 and [4], press fit bearing
a A rough standard pressing force (26) to case (31).
is 30 tons. a A rough standard pressing force is several
ii) Remove oil seal (28) from cover (29). tons.
14 PC400, 450-8R
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, D6 and
2 Periphery of oil seal: [5], 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, 450-8R 15
4. No. 2 carrier assembly a When inserting the pin, do not set the
Assemble the No. 2 carrier assembly accord- 3 claws (a) on the periphery to the
ing 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.
1) Install plate (21) to carrier (16).
2) Install bearing (19) to gear (18) and fit top
and bottom thrust washers (17) and (20),
and then set the gear assembly to carrier
(16).
3) Aligning the pin holes of shaft (15) and
carrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve the
planetary gear and take care not to
damage the thrust washers.
4) Insert pin (14).
a After inserting the pin, caulk the pin

part of the carrier.
2) Install No. 2 carrier assembly (13).
5. Install No. 2 carrier assembly according to the

1) Set No. 2 carrier assembly to case.
2) Tighten bolt (12).
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
343 – 427 Nm {34 – 43.5 kgm}
3) Fit the O-ring to case.
16 PC400, 450-8R
6. No. 2 sun gear

Install No. 2 sun gear (11).
8. No. 1 carrier assembly

7. Ring gear according to the following procedure.
Using the eyebolt (M12 x 1.75), install ring i) Press fit shaft (5) to the carrier in the
gear (10). 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.
a Degrease the mating faces of ring gear
(10) and case (29).
a Never stick gasket sealant to the mating iii) After installing plate (9), install thrust
faces of ring gear (10) and case (29).
3 Mounting bolt:
washer (8), bearing (7), gear (6), and
snap ring (4).
245 – 309 Nm {25 – 31.5 kgm}
a Add engine oil (EO30-CD) at this time.
PC400, 450-8R 17
2) Install No. 1 carrier assembly (3). 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.
2 Mating faces of swing motor

assembly (1) and ring gear:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
9. No. 1 sun gear assembly 4 Swing motor assembly: 115 kg
Install No. 1 sun gear (2).

a Take care not to install the No. 1 sun gear Tighten the drain plug and add engine oil
upside down. (EO30-CD, or SHC 5W-30K for extremely cold
a Install the No. 1 sun gear with the tooth (e) district) through the oil filler to the specified
down. level.
5 Swing machinery case: Approx. 21 l
18 PC400, 450-8R
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, 450-8R 19
SEN04273-00

© 2008 KOMATSU
All Rights Reserved
20
SEN04274-03
PC400, 450-8R
SEN04274-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 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, 450-8R 1
Disassembly and assembly of q Floating seal

carrier roller assembly a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
es of the O-ring and floating seal (hatched
a Only precautions for assembling the carrier roller parts). Take care that dirt will not stick to the
assembly are explained below. floating seal contact surfaces.
a Be sure to use the installer F1 to insert the
Special tools floating seal assembly in the housing.
a After installing the floating seal, check that its
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name slant is less than 1 mm and its projection (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 ton}.
q Carrier roller
a Using tool F2, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the
gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
2 PC400, 450-8R
a Using tool F2, fill the carrier roller assembly

with oil and tighten the plug.
5 Carrier roller: 170 – 180 cc (EO30-CD)
PC400, 450-8R 3
Disassembly and assembly of q Track roller

track roller assembly a Using tool G2, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for 10
a Only precautions for assembling the track roller seconds and check that the pointer of the
assembly are explained below. 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 flange)

85 kg (Double flange)
Assembly
q Floating seal
a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
es of the O-ring and floating seal (hatched a Using tool G2, fill the track roller assembly
parts). Take care that dirt will not stick to the with oil and tighten the plug.
floating seal contact surfaces. 5 Track roller:
a Be sure to use the installer G1 to insert the 280 – 310 cc (Single flange) (EO30-CD)
floating seal assembly in the housing. 280 – 290 cc (Double flange) (EO30-CD)
a After installing the floating seal, check that its 3 Plug: 10 – 20 Nm {1 – 2 kgm}
slant is less than 1 mm and its projection (a)

is 5 – 7 mm.
4 PC400, 450-8R
Disassembly and assembly of 4. Remove floating seal (7) on the opposite side
idler assembly from idler (5) and shaft and support assembly
(6).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 791-575-1520 Installer t 1
H
2 791-601-1000 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

assembly (6).
a Idler is filled with oil of 345 ± 10 cc. Drain it or
spread cloths to soak it at this time.
PC400, 450-8R 5
Assembly a When installing the floating seal, thoroughly

1. Press fit bushings (12) (on both sides) to idler clean, degrease, and dry the contact surfac-
(5). es of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the
2. Fit the O-ring and install support (10) to shaft floating seal contact surfaces.
(11) with bolt (9) and tighten nut (8). a Be sure to use the installer H1 to insert the
floating seal assembly in the housing.
a After installing the floating seal, check that its
slant is less than 1 mm and its projection (a)
is 9 – 11 mm.
a Install the shaft with the UP mark up.
4. Install shaft and support assembly (6) to idler (5).
3. Using tool H1, install floating seal (7) to idler (5)

and shaft and support assembly (6).
5. Similarly, using too H1, install floating seal (4) to

idler (5) and support (3).
6 PC400, 450-8R
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. Using tool H2 , 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, 450-8R 7
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring assembly 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
Symbol
Sketch
Q’ty
N/R
Part number Part name large and dangerous, set the tool se-
curely.
791-685-8006 Compressor t 1 a Installed load of spring:
791-635-3160 Extension t 1 239.037 kN {24,375 kg}
1 Cylinder
790-101-1600 t 1
(680 kN {70 ton})
J 790-101-1102 Pump t 1
790-201-1660 q Plate 1
2
790-101-5021 q Grip 1
01010-50816 q 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 re-
duce 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, 450-8R
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 piston
(10) and secure them with snap ring (13).
2) Tighten valve (12) temporarily and secure it
with lock plate (11).
2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylinder 4) Remove recoil spring assembly (1) from tool
(7). 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 posi-
tion of the valve will be on outside.
a Supply 320 cc of grease (G2-LI) to the cylin-
der, bleed air, and check that the grease
flows out of the grease hole.
PC400, 450-8R 9
Removal and installation of Installation

sprocket
[*1]
Removal 2 Thread of sprocket mounting bolt:
1. Remove track shoe assembly. For details, see Gasket sealant (LG-6)
“Removal and installation of track shoe 3 Sprocket mounting bolt:
assembly”. 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 26 mounting bolts and lift off sprocket

(1). [*1]
4 Sprocket: 70 kg
10 PC400, 450-8R
Expansion and installation of 4. Using tool K, remove master pin (1). [*3]
track shoe assembly
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
791-650-3000 Remover and installer t 1

Cylinder
K 790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
Expansion of track shoe

1. Start the engine and set the master pin to above
the idler. 5. Move the master pin forward and set block [1]
under the track shoe in front of the idler.
2. Remove track shoes (2) on the right and left
sides of master pin (1). [*1] 6. Pull out pusher K.
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 adjust-
ment 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, 450-8R 11
Installation of track shoe 2 Apply grease to the contact faces of dust

q Carry out installation in the reverse order to ex- seal (5) and bushing (4) (all over the end
pansion. face of the dust seal or bushing) (parts
marked Q). Do not apply grease to the
[*1] pars marked (X), however.
2 Mounting bolt: Anti-seizure compound R: Detail of regular pin position
(MARUZEN MOLYMAX No. 2 or equiv- M: Detail of master pin position
alent) (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 de-
tail, see Testing and adjusting, “Checking
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 that [*4]
its projection (a) will be as follows. Set the track shoe and sprocket (4) as shown in
q Dimension (a): 4.4 ± 2 mm 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, 450-8R

revolving frame assembly
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 posi-
tion.
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 mo-
terweight assembly”.
tor (Port T)
q (6): Center swivel joint (Port D) – Hydraulic
3. Disconnect 4 boom cylinder hoses (1). tank
a Plug the hoses to stop oil. q (7): Center swivel joint (Port E) – Solenoid
valve
q (8): Center swivel joint (Port B) – Control
valve left travel (Port B2)
q (9): Center swivel joint (Port D) – Control
valve right travel (Port B5)
q (10): Center swivel joint (Port A) – Control
valve left travel (Port A2)
q (11): Center swivel joint (Port C) – Control
valve right travel (Port A5)
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 opposite
side similarly.
4 Boom cylinder assembly: 360 kg
PC400, 450-8R 13
8. Remove 29 mounting bolts (13), leaving 3 each Installation

at the front and rear sides. q Carry out installation in the reverse order to re-
moval.
[*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 direc-
tion.
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,
erect the engine hood, referring to “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 as-
sembly, take care that it will not interfere
with the center swivel joint assembly.
4 Revolving frame assembly: 10,000 kg
14 PC400, 450-8R
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 tight-
ening.
a Marks (P) and (S) are the soft zone points.

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
Bleed air from the travel motor. For details, see
Testing and adjusting, “Bleeding air from various
parts”.
PC400, 450-8R 15
Removal and installation of 4) Disconnect coaxial cable connector (9) of

counterweight assembly camera 2 (RC2).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Commercially
Impact wrench q 1
available
― Socket wrench
Commercially
(Width across flats: 65 q 1
available
mm)
a Use the impact wrench and socket wrench appli-
cable for the tightening torque for the counter-
weight mounting bolts.
2. Open engine inspection cover at the counter-
3 Mounting bolt: 3,430 – 4,212 Nm {350 – 450 weight side.
kgm} a Because the handle of the cover touches the
counterweight.
Removal
1. Remove the accessories on the counterweight 3. Set eyebolt [1] to counterweight assembly (2).
(Mirror specification) 4. Remove 4 mounting bolts (10). [*1]
1) Remove mirror (1).
2) Sling counterweight assembly (2).
5. Lift off counterweight assembly (2). [*2]

a Check where shims have been used.
(1-rear camera specification) a When lifting off the counterweight, take care
1) Disconnect connector A40 (3) of camera 1 not to strike it against the engine, radiator
(RC1). and cooler assembly, etc.
2) Disconnect connector CN-L09 (5) and wiring 4 Counterweight assembly: 9,500 kg
harness clamps (6) and (7) from rear working
lamp (4).
3) Sling counterweight assembly (2).
(2-rear camera specification)

1) Disconnect connector A40 (3) of camera 1
(RC1).
2) Disconnect connector CN-L09 (5) and wiring
harness clamps (6) and (7) from rear working
lamp (4). (If equipped)
3) Remove cover (8).
16 PC400, 450-8R
Installation
q Carry out installation in the reverse order to re-
moval.
a If heat insulation cover (11) of the engine
compartment is flattened, replace it.
a Precautions in tightening mounting bolts

Temporarily tighten the mouting bolts with
the handwrench, etc right before the counter-
weight seats to the frame.
Then, tighten the mounting bolts to the spec-
ified torque with impact wrench, etc.
[*1]
2 Threads of mounting bolt: Adhesive (LT-2)
3 Mounting bolt (Width across flats: 65 mm):
3,430 – 4,212 Nm {350 – 430 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exterior
parts (horizontal clearance) with shims.
q Maximum shim adjustment clearance: 2
mm
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 counter-
weight will be 10 ± 5 mm evenly.
PC400, 450-8R 17
Attaching procedure for counterweight noise in-

sulation sheet
a Attach the counterweight noise insulation
sheets according to the following procedure.
1. Attach the noise insulation sheets (1), (2), (3),
(4) and (5) to the front surface of the counter-
weight.
a The surface of the counterweight for noise
insulation sheets to be attached should be
degreased and free from rust completely.
2. Attach the noise insulation sheets with the sur-
face (a) which has no SG sheet (black surface)
facing downward.
18 PC400, 450-8R
PC400, 450-8R 19
©2011 KOMATSU
All Rights Reserved
20
SEN04275-01
PC400, 450-8R
SEN04275-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R
PC400-8R 75001 and up
PC450-8R 75001 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 ............................................................................... 12
Removal and installation of oil seal in hydraulic pump input shaft .............................................................. 15
Disassembly and assembly of work equipment PPC valve assembly ........................................................ 16
Disassembly and assembly of travel PPC valve assembly......................................................................... 17
Disassembly and assembly of hydraulic cylinder assembly ....................................................................... 18
PC400, 450-8R 1
Removal and installation of center q (15):Center swivel joint (C port) – Right travel
swivel joint assembly control valve (A5 port)
Removal 3. Pull out pin (16) on the side of center swivel joint
k Release the remaining pressure in the hy- and remove the jam plate from the center swivel
draulic circuit. For details, see Testing and joint.
adjusting, “Releasing residual pressure from
hydraulic circuit”.
a Mark all the piping with tags to prevent mistakes
in the mounting position when installing.
1. Disconnect 6 hoses (1) through (6) between

travel motor and center swivel joint.
q (1):Center swivel joint (T port) – Left travel
motor (T port)
q (2):Center swivel joint (T port) – Right travel
motor (T port)
q (3):Center swivel joint (B port) – Left travel
motor (PA port)
q (4):Center swivel joint (D port) – Right travel
motor (PB port)
q (5):Center swivel joint (A port) – Left travel
4. Remove four mounting bolts (17).
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 9 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) – Hydraulic
tank
q (11):Center swivel joint (E port) – Solenoid
valve
q (12):Center swivel joint (B port) – Left travel
control valve (B2 port)
q (13):Center swivel joint (D port) – Right travel
control valve (B5 port)
q (14):Center swivel joint (A port) – Left travel
control valve (A2 port)
2 PC400, 450-8R
Installation
[*1]
Install the center swivel joint facing in the direction
shown in the diagram. (The diagram shows the ma-
chine as seen from above)
q Refilling with oil (hydraulic tank)

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, 450-8R 3
Disassembly and assembly of 1. Remove cover (1).

center swivel joint assembly
2. Remove snap ring (2).
Special tools
3. Using tool M, pull out swivel rotor (4) and ring (3)
Necessity
from swivel shaft (5).
Symbol
Sketch
Q’ty
N/R
4. Remove seal (6) from swivel shaft (5).
790-101-2501 Push puller t 1
790-101-2510 q Block 1 5. Remove O-ring (7) and slipper seal (8) from
790-101-2520 q Screw 1 swivel rotor (4).
791-112-1180 q Nut 1
M 790-101-2540 q Washer 1
790-101-2630 q Leg 2
790-101-2570 q Plate 4
790-101-2560 q Nut 2
790-101-2650 q 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 care-
ful 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, 450-8R
Removal and installation of 6. Disconnect block (7) together with return hose.
hydraulic tank assembly
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, 450-8R 5
13. Lift off hydraulic tank assembly (16). Installation

4 Hydraulic tank assembly: 200 kg q Carry out installation in the reverse order to re-
moval.
[*1]
3 Mounting bolt:
245.2 – 308.9 Nm {25.0 – 31.5 kgm}

Approx. 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
q Bleeding air
various parts”.
6 PC400, 450-8R
Removal and installation of 5. Disconnect the 2 wiring connectors and 8 hoses.

control valve assembly q (6):A51 (Front pump pressure sensor)
q (7):A52 (Rear pump pressure sensor)
q (8):Port PS hose (Hose band: Yellow-Blue)
Removal q (9):Port PST hose (Hose band: Brown)
k Lower the work equipment to the ground and q (10):Port PPS2 hose (Rear pump, red)
stop the engine. Then, loosen the hydraulic q (11):Port PR hose (Solenoid)
oil filler cap slowly to release the internal q (12):Port PR hose (Pump, yellow)
pressure of the hydraulic tank and set the q (13):Port PP1 hose (Front pump)
work equipment lock lever to the LOCK posi- q (14):Port PP2 hose (Rear pump)
tion. q (15):Port T hose (Oil cooler)
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)
3. Remove partition covers (3), (4), and (5) 7. Remove relay bracket (20) and clamp (21).
between the engine and control valve.
8. Disconnect drain hose (22). (To tank)
9. Disconnect the following 6 left PPC hoses.

q (23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm OUT (Hose band: Yellow)
4. Remove the control valve bottom cover.
PC400, 450-8R 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, 450-8R
17. Sling control valve assembly (40) temporarily Installation

and remove 3 mounting bolts (39). q Carry out installation in the reverse order to re-
moval.

q Bleeding air
various parts”.
18. Lift off control valve assembly (40).

4 Control valve assembly: 250 kg
PC400, 450-8R 9
Disassembly and assembly of

control valve assembly
a Only precautions for assembling the control

valve assembly are explained below.
Assembly
q Apply engine oil to the sliding surfaces of the
parts before installing.
q When installing spools (7) and (10) in the valve
chamber, direct drilled holes (8) and (11) toward
cylinder ports (9) and (12).
q Control valve top and bottom covers

2 Mating faces of control valve top and bot-
tom 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 bot-
tom covers:
156.9 – 176.5 Nm {16 – 18 kgm}
q Merge-divider valve
q Install filters (13) to the bottom of ports PLS1 and 2 Mating face of merge-divider valve:
PLS2 as shown below. SEALEND 242 or equivalent
q Tighten the mounting bolts of the merge-divider
valve similarly to those of the control valve cov-
ers.
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 cov-
ers.
10 PC400, 450-8R
3 Mounting bolt of back pressure valve, q Main relief valve assembly

boom Hi check valve, quick return valve, After installing the main relief valve to the control
lock valve, and arm plate: valve, see Testing and adjusting, “Measuring
58.8 – 73.6 Nm {6 – 7.5 kgm} and adjusting oil pressure in work equipment,
swing, and travel circuits”.
PC400, 450-8R 11
Removal and installation of 2. Remove the hydraulic tank strainer. Using tool
hydraulic pump assembly C, stop the oil.
a When not using tool C, remove the drain plug
to drain the oil from the hydraulic tank and
Special tools piping.
6 Hydraulic tank:Approx. 335 l
Necessity
Symbol
Sketch
Q’ty
N/R
796-460-1210 Oil stopper q 1

C
796-770-1320 Adapter q 1
Removal
k Lower the work equipment to the 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 cable from the negative (–)
terminal of the battery.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.
3. Drain the oil from the flywheel housing.
1. Remove 2 lower covers (1).
4. Open the main pump side cover.
5. Open the engine hood.
6. Lift off covers (2) and (3) together.
8. Remove stay (5).
12 PC400, 450-8R
9. Disconnect the following 2 pump wiring connec- 11. Sling hydraulic pump assembly (18) temporarily
tors. 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 8 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]
4 Hydraulic pump assembly: 260 kg
(Band color: Red)
q (15):Front pump pressure input port hose
q (16):Pump suction port tube
PC400, 450-8R 13
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
2 Hydraulic pump involute spline:
Anti-friction compound (LM-G)
2 Mating face of hydraulic pump case:

3 Flywheel housing drain plug:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}

Approx. 335 l
Quantity of oil in tank (Center of oil level
gauge): 248 l
q Bleeding air
various parts”.
14 PC400, 450-8R
Removal and installation of oil Installation

seal in hydraulic pump input shaft
[*1]
Removal 2 Oil seal lip portion: Grease (G2-LI)
1. Remove the hydraulic pump assembly. Refer to 2 Oil seal outer circumference: Grease (G2-LI)
the “Removal of hydraulic pump assembly” a Coat the oil seal outer circumference thinly
section. with grease.
a Press-fit oil seal (3), using tool [1].
2. Remove snap ring (1) and then remove spacer
(2).
3. Pry off oil seal (3) with a screwdriver. [*1]

a When attempting to pry off the seal, do not
damage the shaft.
PC400, 450-8R 15
Disassembly and assembly of a When installing pistons (8), apply grease to

work equipment PPC valve their outside and the inside of the valve body
holes.
3 Mounting bolt of plate (5):
assembly
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a Only precautions for assembling the work equip- 2 Sliding parts of joint (4):
ment PPC valve assembly are explained below. 2 – 4 cc of Grease (G2-LI)
2 Female threads of body (A):
Adhesive (LT-2)
a Apply a drop (about 0.02 g) of LOCTITE to

each of the 2 threaded parts of the body as
shown in the figure, and then tighten joint (4).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
a Observe the tightening torque of the joint.
2 Contact parts of piston and disc (2):

Grease 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 69 – 88 Nm {7 – 9 kgm}
a When installing disc (2), adjust the play to 0.5

– 3 mm at 200 mm from the turning center of
the lever.
Assembly
q Work equipment PPC valve assembly
a Install springs (11) with the small-diameter
(inside diameter) end on the shim (12) side.
a Springs (10) having different number of turns
are used for the following hydraulic ports.
Take care when installing them.
Installed height: 31.9 mm (Common to all
springs)
Installed load:
P1, P2: 35.3 N {3.6 kg}
P3, P4: 21.6 N {2.2 kg}
a The position of each port is stamped on the

underside of valve body.
2 Piston (8): Grease (G2-LI)
16 PC400, 450-8R
Disassembly and assembly of

travel PPC valve assembly
Disassembly
a Only precautions for assembling the travel PPC
valve assembly are explained below.
Assembly
q Travel PPC valve assembly
a Insert shim (3) of the thickness and quantity
checked when disassembled.
Standard shim thickness: 0.3 mm
a Since spring (4) is not symmetric vertically,
install it with the small-diameter (inside diam-
eter) end on the shim side.
2 Periphery of piston (7) and inside of
hole of body (1): Grease (G2-LI)
2 Sliding part of shaft (13) (4 – 8 cc),
contact parts of lever (12) and piston
(7), and contact part of pin of lever
(26) and plate (24) (0.3 – 0.8 cc):
Grease (G2-LI)
a Use the inserting jig described in

KES.D.07177 to insert bushing (19). Do not
drive in pin (18), bushing (19) by hitting it di-
rectly with a hammer.
PC400, 450-8R 17
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1. Piston rod assembly
1) Remove the piping from the cylinder
assembly.
Special tools
2) Remove the mounting bolts and disconnect
Necessity
cylinder head assembly (1).
Symbol
Sketch
Q’ty
N/R
Part number Part name 3) Pull out piston rod assembly (2).
a Put a container under the cylinder to re-
1 790-502-1003 Cylinder repair stand t 1 ceive oil.
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring (For boom and
796-720-1680 q 1
bucket)
Clamp (For boom and
4 07281-01589 q 1
bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
q Push tool
790-201-1851 1
(For bucket)
q Push tool
N 790-201-1861 1
5 (For boom)
q Push tool
790-201-1871 1
(For arm)
790-101-5021 q Grip 1 4) Disassemble the piston rod assembly
01010-50816 q Bolt 1
790-101-5021 q Grip 1 1] Set piston rod assembly (2) to tool N1.
01010-50816 q Bolt 1
q Plate
790-201-1660 1
6 (For bucket)
q Plate
790-201-1670 1
(For boom)
q Plate
790-201-1680 1
(For arm)
2] Remove piston assembly lock screw (3).

a This work is common to the boom,
arm, and bucket cylinders.
Screw size: M12×1.75
18 PC400, 450-8R
3] If screw (3) is so caulked that you cannot

remove it, tighten it temporarily and tap
the threads on it, and then remove it.
8] Remove cap (8), 11 balls (9), and plunger

(10).
q Perform this work for only the arm cyl-
4] Using tool N2, remove piston assembly inder.
(4). a Since cap (8) is made of nylon, tighten
q When not using tool N2, loosen the a screw into it and pull it with pliers.
piston assembly by using the drilled
holes (f10: 2 places) (in which the
pins of N2 are inserted in the following
figure).
5] Remove plunger (5).
q Perform this work for only the boom
and arm cylinder.
6] Remove collar (6).
and arm cylinder.
7] Remove head assembly (7).
PC400, 450-8R 19
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.
a Clean the all parts. After installing them, cover
3) Remove piston ring (13).
the piping ports and pin holes to prevent dirt from
4) Remove the O-ring and backup rings (14).
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). 1. Assembly of cylinder head assembly
3) Remove rod packing (18). 1) Using tool N5, press fit bushing (20).
4) Remove buffer ring (19). 2) Install buffer ring (19).
5) Remove snap ring (21). 3) Install rod packing (18).
6) Remove bushing (20). 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).
20 PC400, 450-8R
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. (Refer to the
a Set piston ring (13) to tool N3 and turn the procedure 1 - 4) of disassembly.)
handle 8 – 10 times to expand the piston 2) Install cylinder head assembly (7) to the
ring. piston rod.
2) Set tool N4 and contract piston ring (13). 3) Fit the O-ring and backup ring to collar (6),
and then install them.
q Perform this work for only the boom and
arm cylinders.
4) Install plunger (5).
q Perform this work for only the boom and
arm cylinders.
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.
2 Ring groove: Grease (G2-LI)
5) Set plunger (10) to the piston rod. Install 11
balls (9) and secure them with cap (8).
a After installing the plunger, check that it
has a little play at its end.
q Perform this work for only the arm cylin-
der.
PC400, 450-8R 21
6) Assemble piston assembly (4) according to 3] Make a screw hole to install screw (3).
the following procedure. a Apply a drill to the V-groove of the
q When reusing the rod and piston as- threaded parts of piston (4) and rod
sembly (4) (2) and make a hole.
1] Tighten piston assembly (4). Then, using a When making a hole on the cylinder
tool N2, tighten piston assembly (4) until (arm cylinder) having the bottom
the screw holes are aligned. cushion, make it around the cushion
a Remove the burrs from the threads plug.
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 hole Tapping

depth depth
Bucket/Boom 27 20
Arm 36 29
4] Tighten screw (3).

a Clean the parts thoroughly and re-
move metal chips, dirt, etc.
2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:
q When replacing either or both of
the rod and piston assembly (4)
with new ones 58.9 – 73.6 Nm {6 – 7.5 kgm}
a Make a mark of the cushion plug posi- 5] Caulk the threaded part [1] by 4 places
tion on the end of the rod having the with a punch.
bottom cushion.
q Perform this work for only the arm cyl-
inder.
2] Using the tool, tighten piston assembly
(4) until it reaches the end of the rod.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check that
plunger (5) has some play.
and arm cylinders.
22 PC400, 450-8R
7) Install piston rod assembly (2).

a Set the abutment joint of the ring at a side
and insert the piston rod, aligning it with
the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.
8) Tighten the mounting bolts of cylinder head

assembly (7).
3 Mounting bolt:
Cylinder name Tightening torque

Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm}
Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54 ± 8 kgm}
9) Install the piping.
PC400, 450-8R 23
©2009 KOMATSU
All Rights Reserved
24
SEN04276-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
PC400, 450-8R 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
Symbol
Sketch
ting on the bottom side.
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, 450-8R
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:
PC400-8R, PC400LC-8R: 7,400 kg Anti-friction composition (LM-P)
PC450-8R, PC450LC-8R: 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, 450-8R 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”.

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.
4 PC400, 450-8R
PC400, 450-8R 5
SEN04276-00

© 2008 KOMATSU
All Rights Reserved
6
SEN04277-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Cab and its attachments
Removal and installation of operator cab assembly ....................................................................................... 2
Removal and installation of operator cab glass (stuck glass) ......................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
Removal and installation of floor frame assembly ........................................................................................ 22
PC400, 450-8R 1
Removal and installation of 9. Remove rear covers (10) to (13).

operator cab assembly
Removal
k Disconnect the negative terminal (–) of the
battery before starting the work.
1. Remove front window (1).

2. Remove step plate (2).
3. Remove floor mat (3).
4. Refer to “Removal and installation of monitor

assembly”, and remove monitor assembly (4).
5. Remove covers (5) and (6). 10. Remove duct (14).

6. Remove cover duct assembly (7). 11. Remove cover (15).
a Disconnect connector H15 fixed on the
back from the clip.
7. Insert key (8), turn it right, and open the out-

side-air filter cover.
8. Remove outside-air filter (9).

14. Remove lock pin (18) and remove duct (19).
2 PC400, 450-8R
15. Remove duct (20). 23. Remove ducts (32) and (33).
16. Disconnect connector L03 (21). a Cut tie-wrap.
17. Remove plates (22) and (23) from the operator 24. Disconnect wiper motor connector M05(34).
cab. 25. Remove harness (35) and antenna (36) from
the cab wall.
a Cut 2 points of tie-wrap.
18. Disconnect connectors K01(25) and CK02

(26).
19. Pass over and disconnect antenna (24) from 26. Remove duct (37).
KOMTRAX communication modem (K). 27. Remove duct (38) upper and lower.
20. Disconnect connector M10(27) from the opera-
tor's cab. (If equipped)
21. Disconnect cab wiring intermediate connectors

H09(28), H08(29), and H16(30).
a Cut tie-wrap (T),
22. Disconnect radio antenna (31).
a (23) is removed plate.
28. Disconnect window washer hose (39).

29. Disconnect harness clamp (40).
30. Haul in antenna (36).
PC400, 450-8R 3
31. Detach harness clamp (41) from the right back 35. Lift off and remove operator cab assembly
side of operator cab. (47).
4 Operator cab assembly: 470 kg
32. Remove bolt (42) under the operator cab and

remove lock plate (43). [*1]
33. Remove bolt (44). [*2]
Installation
q Installation is done in the reverse order of
removal.
[*1]
3 Mounting bolt of lock plate (43):
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Bolt (44):
245 – 309 Nm {25 – 31.5 kgm}
34. Dismount 6 mounting bolts (45) and 4 mount-

ing nuts (46).
a Check the bolt length beforehand.
4 PC400, 450-8R
Removal and installation of operator cab glass (stuck glass)
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator cab, 5 panes (1) to (4) and (2) : Left side rear window glass
(18) are stuck. (3) : Door lower window glass
a In this section, the procedure for replacing the (4) : Front window glass
stuck glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Dam rubber
replace only the front window glass while the (17) : Center trim seal
front window assembly is installed to the opera- (18) : Rear glass
tor cab.)
a For the procedure for replacing the front win-
dow assembly, see “Removal and installation of
front window assembly”.
PC400, 450-8R 5
Special tools (The figure shows the operator cab of a wheel

loader.)
Necessity
Symbol
Sketch
Q’ty
N/R
2 793-498-1210 Lifter (Suction cup) t 2
X
3 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator cab
(metal sheet)(8).
a If the window glass is broken finely, it may

be removed with a knife [4] and a screw-
driver.
a Widening the cut with a flat blade screw-
driver, cut the dam rubber and adhesive
with knife [4].
(The figure shows the operator cab of a wheel

loader.)
a If a seal cutter is not available, make holes

on the adhesive and dam rubber with a
drill and pass a fine wire (piano wire, etc.)
[2] through the holes. Then, grip the both
ends of the wire with priors [3], etc. (or
hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and dam rubber.
Since the wire may be broken by the fric-
tional heat, apply lubricant to the wire.
2. Remove the window glass.
6 PC400, 450-8R
Installation a Even if the primer is packed again just

1. Using a knife and scraper [5], remove the after it is unpacked, use it within 24 hours
remaining adhesive and dam rubber from the after it is unpacked for the first time.
metal sheets (glass sticking surfaces) of the (Discard the primer 24 hours after it is
operator's cab. unpacked.)
a Remove the adhesive and dam rubber to 1) Stir the primers for both of paint and glass
a degree that they will not affect adhesion sufficiently before using them.
of the new adhesive. Take care not to a If the primer has been stored in a refrig-
scratch the painted surfaces. erator, leave it at the room temperature
(If the painted surfaces are scratched, for at least half a day before stirring it.
adhesion will be lowered.) (If the primer is unpacked just after
taken out of the refrigerator, water will
(The figure shows the operator cab of a wheel be condensed. Accordingly, leave the
loader.) 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 and glass primer.
2. Remove oil, dust, and dirt, etc. form the stick-

ing surfaces of operator cab (8) and window
glass (9) with white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave 3) Evenly apply the paint primer to the surfaces
them for at lease 5 minutes to dry. to stick dam rubber and its outside surfaces
(The figure shows the operator's cab of a wheel to apply adhesive on operator cab (8).
2 Paint primer:
loader.)
Sunstar primer for painting plane
580 super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
3. Apply primer (10).

a The using limit of primer is 4 months after
the date of manufacture. Do not use the
primer after this limit.
a Use the primer within 2 hours after un-
packing it.
PC400, 450-8R 7
a Parts to be coated with primer; Apply the prim- a Never apply the wrong primer.
er all over dimension (a). If the glass primer, etc. is applied by mistake,
q Dimension to apply primer (a): 25 mm wipe it off with white gasoline.
4) Apply the glass primer to the sticking sur-

faces of window glass (9).
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
a In addition to the above parts, additionally

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.
a Parts to be coated with primer; Apply
the primer to all around of sticking
surface (d) of window glass (9) for
dam rubber (6) installation position
and operator cab (8).
a Do not apply the primer to the
boarder about 5mm wide between the
black part and transparent part of the
glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply the wrong primer.
If the paint primer, etc. is applied by
mistake, wipe it off with white gaso-
line.
8 PC400, 450-8R
4. Stick dam rubber (both-sided adhesive a Stick dam rubber (6a) additionally to
tape)(6) along the inside edge of the glass right side window glass (1).
sticking section. q Positions to stick additional dam rub-
a Do not remove the release tape of dam ber to the right side window glass:
rubber on the glass sticking side before (f): 50 mm
sticking the glass. (g): 90 mm
a When sticking the dam rubber, do not (h): 250 mm
touch the cleaned surface to the utmost.
a Care should be taken not to float the dam
rubber of each sticking corner.
2) Stick dam rubber (6) for left side window

glass (2) to the position as shown in the
figure.
a When sticking dam rubber (6) around a
frame, do not lap its finishing end over the
starting end. Or, make clearance of about
5 mm between them (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
PC400, 450-8R 9
3) Stick dam rubber (6) for door lower win- a Stick dam rubber (6c) of the lower
dow glass (3) to the position as shown in side of the front window glass along
the figure. the outside edge of the lower line, dif-
ferently from other dam rubbers (6).
(If it is stuck along the inside, it will be
seen through the transparent part of
the glass.)
a Stick dam rubber (6b) additionally to

door lower window glass (3).
q Positions to stick additional dam
rubber to the door lower window
class: 5. Position the new window glass.
(j) : 110 mm 1) Check the clearance between the window
(k) : 90 mm glass and the operator cab on the right,
(m) : 200 mm left, upper, and lower sides, and then posi-
tion the window glass to be the clearances
evenly.
2) Stick tapes [6] between window glass (9)
and operator cab (8) and draw positioning
line (n).
a Stick tapes [6] for positioning to 3
points, that is, right, left and lower
parts of the right side window glass,
left side rear window glass, and door
lower window glass for accurate posi-
tioning.
3) Cut the tape between window glass (9)
and operator cab (8) with a knife, etc. and
then remove the window glass.
4) Stick dam rubber (6) for front window a Do not remove the tapes left on the
glass (4) to the position as shown in the window glass and the operator cab
figure. before installing the window glass.
10 PC400, 450-8R
a When positioning front window glass

2) Cut the tip of the adhesive nozzle (14) so
(4), set its horizontal position to the
frame width. that dimensions (q) and (r) will be as fol-
And set its vertical position to make lows.
q Dimension (q): 10 mm
the height difference (p) between the
q Dimension (r): 15 mm
frame top and the front window glass
3 mm.
3) Set adhesive cartridge (12) to caulking

6. Apply adhesive. gun [7].
a Use either of two types of adhesives a An electric caulking gun is more effi-
according to the season. cient.
2 Adhesive (Apr. to Oct.):
Sunstar penguine seal 580 super “S”
or equivalent
2 Adhesive (Oct. to Apr.):
Sunstar penguine seal 580 super “W”
or equivalent
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 form the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
PC400, 450-8R 11
4) Remove the release tape of dam rubber

on the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator cab.
a Apply adhesive (15) with dimensions

(s) and (t) for dam rubber (6) of oper-
ator cab (8).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) higher than dam
rubber (6).
a Apply the adhesive evenly with same
height level.
7. Install the window glass.

1) Install window class (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be
removed and stuck again, stick it with
utmost caution.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber
a Apply adhesive (15) additionally to closely.
additional dam rubber (6a) of right a Press the corners of the window glass
side window glass and additional dam firmly.
rubber (6b) of door lower window
glass.
12 PC400, 450-8R
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X2.
a After installing front window glass (4),

fill the clearances between it and cen-
ter trim seal (16) with caulking mate-
rial in range (s) with dimensions (t)
and (u).
After applying the primer to glass (4)
of section A-A, apply the adhesive as
caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, mask the glass side
and form the adhesive with a rubber
spatula as shown in the figure.
a Wipe off the projected adhesive.
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
2 Adhesive:
SUNSTAR penguine seal 580
super “S” or “W” or equivalent
PC400, 450-8R 13
8. Fix the window glass. 9. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator cab and window glass.
X3 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
a When cleaning the glass, do not give an
impact on 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 humidity of
60%)
2) After removing the stopper rubbers, sty-
rene foam blokes, and rubber bands, wait
at least 14 hours, that is, at least 24 hours
in total, before operating the machine
actually.
2) By using styrene foam blocks [9] and rub-

ber bands [10], fix the window glass and
the dam rubber to fit them completely.
14 PC400, 450-8R
Removal and installation of front

window assembly
k Lower the work equipment completely to
the ground and stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the oper-
ator's cab. The procedure for removing and
installing the front window assembly (front
frame and front window glass) is explained
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 block (1) and right corner

block (2). [*1]
a Mounting bolt (4) and washer (3) for left

corner block are used to hang the pull-up
assist cable in the following step 6.
6. Remove left lower pin (7). [*2]

a By removing left lower pin (7), plate (8) at
the end of pull-up assist cable (9) comes
off.
a Hang plate (8) on the mounting bolt of left
corner block (use washer) and set in
place.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator cab.
3. Release the rear lock of the operator cab. Accordingly, take care when removing
left lower pin (7) to disconnect pull-up
4. Lower the front window assembly carefully a assist cable (9).
little. Put out rollers (5) and (6) under the both
sides of the front window through the portion
from which the corner blocks were removed in
the above step 2. (the portion where the rail is
open) and hold them.
5. Remove rollers (5) and (6) under the both

sides of the front window.
PC400, 450-8R 15
9. Twist front window assembly (10) to the right

and left to remove both upper rollers (11) and
(12) from the rails, and then remove front win-
dow assembly (10).
7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower
it gradually.
8. Lower front window assembly (10) completely.

a Do not let the front window assembly
touch the monitor.
16 PC400, 450-8R
Installation a Install the right corner block so that clear-

q Carry out installation in the reverse order to ance (a) between the rail and right corner
removal. block (2) becomes 0 – 2.0 mm.
a Install the right corner block so that there
[*1] is no level difference at the rolling surface
q Adjust opening and closing of the front window (R) of the roller.
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 that the
rollers are not hitched.
2. If there is any problem in opening and closing
of the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not
mounted on the angle.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
5. Install left corner block (1).

a Fully tighten the block after adjusting the
“Close” position in the following step 6.
a Install the left corner block so that clear-
ance (b) between the rail and left corner
block (1) becomes 0 – 2.0 mm.
a Install the left corner block so that there is
no level difference at the rolling surface
(R) of the roller. (Refer to the above fig-
ure.)
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are securely fastened.
4. Install right corner block (2).

a Fully tighten the block after adjusting the
“Close” position in the following step 6.
PC400, 450-8R 17
6. Adjust the “Close” position of the front window

assembly lock according to the following pro-
cedure.
1) Tighten left and right corner blocks (1) and
(2) at roughly right positions so that front
window glass (14) is attached firmly to
cab-side trim seal (15).
7. After the adjustment, splash water heavily over

the front window glass and check that the
water does not leak into the operator cab.
2) Check the working condition of right and

left locks (16) and (17) when opening and
closing the front window assembly.
q If right and left locks (16) and (17) do
not work normally.
1] Loosen lock fitting bolt (18), move
lock (16) forward, and then tighten the
bolt again.
a The same applies to the right
side.
2] After moving the lock, recheck the fit-
ness of front window glass (14) and
cab-side trim seal (15) which was
checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and
the working condition of locks (16)
and (17) are both acceptable, and
then tighten the mounting bolts of the
right and left corner blocks.
18 PC400, 450-8R
8. Adjust the “Open” position of the front window 3) Close front window assembly (10).
assembly lock. 4) Loosen locknut (20) of right and left side of
1) After adjusting the “Close” position of the rubber stoppers (18), and then pull back
front window assembly lock in steps 6 and both rubber stoppers (18) so that they
7, raise the front window assembly to the won't contact with the front window
ceiling. assembly when it is in “Open” position.
2) Set the front window assembly locks at
the both sides of rear of the operator cab
to the “Open” position, and then check the
following items.
q Check the working condition of right
a nd left lo cks (1 6) an d ( 17 ) ( as
explained above).
q Front window assembly must be in
contact with the right and left rubber
stoppers (18) and furthermore, must
be pushing them backward for 1.5 –
3.0 mm.
q The front window assembly must be
pushing the limit switch backward for
4 – 7 mm. 5) Loosen both sides of locknuts (22), and
a The position of limit switch (19) can- adjust the position of striker bolt (21).
not be adjusted. Therefore, the a Striker bolt (21): M10
“Open” position of the front window Inner diameter of plate (23): ø 14.5
assembly is decided within the range mm
where this switch works.
a Limit switch (19) is used to prevent
the windshield wiper from moving
when turning the wiper switch on by
m i s ta k e w h e n t h e f r o n t w i n d o w
assembly is in “Open” position. If the
wiper operates when there is no glass
in the front, the wiper falls down
inside the cab and causes trouble.
To check whether limit switch (19) is
working, turn the key switch on and
see that, even if the wiper switch is
turned on, the wiper does not operate
when the front window assembly is in
“Open” position.
1] Front window assembly (10) must be
pushing the limit switch backward for
4 – 7 mm (at “Open” position).
2] Working condition of lock (17).
q After checking the above items, if it

becomes necessary to do the adjust-
ment.
PC400, 450-8R 19
6) Adjustment of right and left rubber stop- 4] Tighten locknuts (20) of the both
pers (18). sides of rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in “Open” position) into
contact with right and left rubber stop-
pers (18).
9. Adjust stopper (24) of the front window assem-

bly.
1) Adjust and lock both sides of stopper (24)
2] Close front window assembly (10). so that when pulling up the front window
3] Turn right and left rubber stoppers assembly, surface (d) of stopper (D) of
(18) to the left for one and a half front window assembly (10) is in contact
rotation. with surface (c) of stopper (24).
a One turn of rubber stopper (18)
to the left is equivalent to
squashing the rubber for approxi-
mately 1.5 mm.
a When the front window assembly
is in “Open” position, the front
window assembly must be push-
ing right and left rubber stoppers
(18) for 1.5 – 3.0 mm.
20 PC400, 450-8R
10. Check the operating effort of the lock of the

front window assembly.
1) After finishing the adjustment of steps 6 –
9, check that latching efforts of both right
and left locks (16) and (17) are even.
a Check the latching efforts on both
“Close” side (in the front of the opera-
tor cab) and “Open” side (in the rear
of the operator's cab).
[*2]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC400, 450-8R 21
Removal and installation of floor 5. Disconnect ground (2).

frame assembly
Removal
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 6. Disconnect the following PPC hoses from the
a Never release the refrigerant (R134a) to the travel PPC valve. The color of the band is;
atmosphere. q (3): Red
q (4): No color
k If refrigerant gas (R134a) gets in your eyes, q (5): Green
you may lose your sight. Accordingly, put q (6): Blue
on protective goggles while you are collect- a Prepare an oil sump.
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant 7. Disconnect top and bottom of connector (7).
(R134a). Collecting and filling work must be Top: P09
conducted by a qualified person. Bottom: P10
1. Turn the upper structure by 90°.
2. Drain the engine coolant.

3. Remove the operator's cab assembly by refer-

ring to “Removal and installation of operator's
cab assembly”.
22 PC400, 450-8R
q Step 8 – 10 is optional (for breaker). 20. Remove clamps (24) and (25). [*2]
8. Disconnect the following PPC hoses from the 21. Disconnect clamp (26). (If equipped)
PPC valve. The color of the band is;
q (8): Yellow
q (9): No color
a Plug the hose to stop oil flow-out.
9. Disconnect connectors S11 (10) and S10 (11).
10. Disconnect connectors P13 (12) and V30 (13).
22. Disconnect connectors N10 (27) and AC01

(28).
23. Disconnect connectors ECU10 and ECU11
( 2 9 ) f r o m t h e a ir c o n d i t i o n e r c o n t r o l l e r
(ACCONT).
24. Cut tie-wrap (30) and draw in wiring harness
11. Disconnect ground (14). From the left, (31).
T04, T05, T06, T07, T09, T10 25. Disconnect the clamp of wiring harness (32).
12. Disconnect clamp (15).
13. Disconnect connector A08 (16) from the clip.
14. Disconnect connector P17 (17) from the air
conditioner tube.
15. Remove the clamp and disconnect spacer
(18).
16. Disconnect hose (19).
a Check the connecting point.
a Disconnect the work equipment PPC hose
(P) at joint box side. (See item 33.)
26. Disconnect connector H15 (33).

27. Remove grommet (34).
28. Move wiring harness (35) to the outside of the
floor frame.
a (SP) is made of sponge.
17. Disconnect hose (20).

18. Disconnect heater hose (21).
19. Remove mounting bolt (22) and disconnect air
conditioner tube (23). [*1]
PC400, 450-8R 23
29. Disconnect the clamp of wiring harness (35).

30. Move plates (36) and (37) together with wiring
harness (35) to the boom side.
34. Pull out PPC hose assembly (41) of the work

equipment.
31. Open the engine hood and remove cover (38).
35. Sling floor frame assembly (42) and remove it.

a Make sure that the hoses, connectors,
32. Disconnect clamp (39). clamps, and so on are disconnected with-
out fail.
4 Floor frame assembly: 250 kg
33. Disconnect PPC hose (40) of the work equip-
ment. From the top, the color of the band is:
White
Brown
None
Blue
Black
Green
Red
Yellow
a Prepare an oil sump.
24 PC400, 450-8R
Installation
removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexel:
ZXL100PG (PAG 46 or equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
PC400, 450-8R 25
SEN04277-00

© 2008 KOMATSU
All Rights Reserved
26
SEN04278-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and installation of KOMTRAX communication modem assembly.................................................... 5
Removal and installation of monitor assembly................................................................................................ 6
Removal and installation of pump controller assembly ................................................................................... 8
Removal and installation of engine controller ............................................................................................... 10
PC400, 450-8R 1
Removal and installation of air 7. Pull down opening and closing lever (8) of the
conditioner unit assembly outside air filter cover.
8. Remove outside air filter (9).
Removal
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose
when the coolant temperature in the radia-
tor is high, you may be scalded. In this
case, wait until the coolant temperature
lowers and then disconnect the heater
hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the 9. Remove rear covers (10) to (13).
atmosphere.
k If refrigerant gas (R134a) gets in your

eyes, you may lose your sight. Accord-
ingly, put on protective goggles while you
are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the
refrigerant (R134a). Collecting and filling
work must be conducted by a qualified
person.
1. Turn the upper structure by 90°.
2. Drain the engine coolant.

3. Remove front window (1).

4. Remove step plate (2).
5. Remove floor mat (3).
6. Remove covers (5) and (6).
2 PC400, 450-8R
10. Remove duct (14).

a Disconnect connector H15 fixed on the
back from the clip.
16. Remove ducts (22) and (23).

a Cut tie-wrap.
17. Remove duct (24) upper and lower.
18. Remove duct (25) upper and lower.
13. Remove plate (17). 19. Disconnect plate (26) from the cab wall.
14. Remove lock pin (18) and remove duct (19).
15. Remove ducts (20) and (21). 20. Disconnect connectors N10 (27) and AC01
a Cut tie-wrap. (28).
21. Disconnect connectors ECU10 and ECU11
( 2 9 ) f r o m t h e a ir c o n d i t i o n e r c o n t r o l l e r
(ACCONT).
22. Loosen tie-wrap (30) and draw in wiring har-

ness (31).
PC400, 450-8R 3
23. Remove cover (32). Installation

removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexel:
24. Remove mounting bolt (33) and disconnect air ZXL100PG (PAG 46 or equivalent)).
conditioner tube (34). [*1] 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
25. Disconnect heater hose (35).

a Check the connecting point. q Filling air conditioner circuit with refriger-
ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
26. Remove the 7 mounting bolts and air condi-

tioner unit assembly (36).
4 PC400, 450-8R

KOMTRAX communication
modem assembly
Removal
1. Remove covers (1) – (4).
2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors K01(6) and CK02 (7).
4. Remove the 4 mounting bolts and KOMTRAX
communication modem assembly (8).
Installation
removal.
PC400, 450-8R 5

monitor assembly
Removal
1. Remove cap (1).

2. Remove cover (2) and then disconnect wiring
connector P31 (3) for air conditioner sunlight
sensor (S).
3. Remove duct (4).
4. Remove cover (5) as follows. [*1]
1) Insert flat-head screwdriver inside slit (SL)
and push it upward. 5. Remove the 4 mounting bolts and lift monitor
2) Release lock (L) and remove the cover. assembly (6). [*2]
3) Disconnect wiring connector M04 of the 6. Disconnect connectors CM01 (7), CM02 (8)
cigarette lighter from the back of cover (5). and CM03 (9).
a Since CM02 (8) and CM03 (9) can be
installed reversely, be careful not to mis-
take. CM 03 (9) is a green connector.
7. In the case of rear camera specification, dis-
connect connector CN-5 (11).
8. Disconnect connector (10).
6 PC400, 450-8R
Installation
[*1], [*2]
1) Temporarily install monitor assembly (6) with 4
mounting bolts, and then install cover (5).
2) With cover (5) installed, tighten the mounting
bolts of monitor assembly.
q Carry out the rest of installation in the reverse

order to removal.
PC400, 450-8R 7
Removal and installation of pump

controller assembly
Removal
Installation
q Installation is done in the reverse order of re-
moval.
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2. Disconnect relay R08 (4) from the clip.
2) Move lever (3) up.
3. Disconnect bracket (5) and put it to the right
side.
4. Disconnect wiring connectors C01 (6) and C02
(7) as follows.
q Tilt lock (L12) inside while pressing lock
(L1).
a Bar (B) comes out and the lock is re-
leased.
5. Remove the 4 mounting bolts and pump con-
troller assembly (8).
3) Lightly push part (A) of connector cover

(1) from both sides to unfasten claw (B).
4) Remove connector cover (1) around claw
(C).
8 PC400, 450-8R
a Connector without connector cover 3) Set claw (C) to the connector and place
(1) connector cover (1).
a Take care that wiring harness (5) will
not be caught.
2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
possible. 4) Set claw (B) and install connector cover
(1).
a Right and left sliders (4) pushed in as

far as possible (Left figure) 5) Bind connector cover (1) and wiring har-
2) Move lever (3) of connector cover (1) from ness with a new cable tie. (See 1. 1).)
the upper position to the left position (lock
position) in the figure.
a (B), (C): Claws
a If the sliders and lever are not set as
shown in the following figure, the con-
nector is not disconnected or locked
securely with the lever. Accordingly,
check their positions again.
PC400, 450-8R 9

engine controller
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open the engine hood.
2. Disconnect connectors EC01 (1), ENG (2), and

CE03 (3).
3. Remove engine controller (4).
Installation
removal.
10 PC400, 450-8R
PC400, 450-8R 11
SEN04278-01
PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R Hydraulic excavator

© 2010 KOMATSU
All Rights Reserved
12
SEN04280-00
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
PC400, 450-8R 1
SEN04280-00 90 Diagrams and drawings
2 PC400, 450-8R
Hydraulic circuit diagram
Hydraulic circuit diagram PC400, 400LC-8R, PC450, 450LC-8R 1 PC400, 400LC-8R, PC450, 450LC-8R
SEN04280-00
PC400, 450-8R 3
PC400, 450-8R 5

© 2008 KOMATSU
All Rights Reserved
6
SEN04281-01
PC400-8R
PC400LC-8R
PC450-8R
PC450LC-8R

PC400-8R 75001 and up
PC450-8R 75001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Connector arrangement diagram .................................................................................................................. 13
PC400, 450-8R 1
2 PC400, 450-8R
Electrical circuit diagram (1/5)
Electrical circuit diagram (1/5) PC400,400LC-8R,PC450,450LC-8R
SEN04281-01
PC400, 450-8R 3
SEN04281-01
PC400, 450-8R 5
SEN04281-01
PC400, 450-8R 7
SEN04281-01
PC400, 450-8R 9
SEN04281-01
PC400, 450-8R 11
Connector arrangement diagram
PC400, 400LC-8R, PC450, 450LC-8R
Connector arrangement diagram PC400, 400LC-8R, PC450, 450LC-8R
Connector Number Arrangement Connector Number Arrangement

Type Component name Type Component name
No. of pins drawing No. of pins drawing
A13 DT 2 Intermediate connector (Working lamp wiring harness) F-1 P02 X 2 Boom lower PPC oil pressure switch L-2
A22 DT 2 Intermediate connector H-9 P03 X 2 Right swing switch L-2
A40 DT 4 Rear camera 1 K-9 P04 AMP 3 Arm in PPC pressure sensor L-2
A41 DT 4 Camera 2 H-9 P05 X 2 Bucket dump PPC pressure sensor L-1
A42 DT 4 Camera 3 P06 X 2 Boom raise PPC pressure sensor L-1
A43 S 8 Monitor cable V-1 P07 X 2 Left swing switch L-1
A71 D 2 Fuel supply pump F-9 P08 X 2 Arm out PPC oil pressure switch L-1
A72 D 2 Switch box G-9 P09 X 2 Travel PPC oil pressure switch T-1
A73 D 2 Intermediate connector (pair with M24) F-9 P10 X 2 Travel steering PPC oil pressure switch T-1
AC01 — 8 A/C unit Y-3 P13 X 2 Intermediate connector R-1
CE01 DRC 60 Engine controller AK-6 P14 X 2 Service pressure switch (if equipped) R-2
CE02 DRC26-50S40 50 Engine controller AK-5 P15 X 2 Service pressure switch (if equipped) R-1
CE03 DTP 4 Engine controller AK-6 P17 S090 2 A/C HI/LO pressure switch U-1
CK01 070 14 KOMTRAX terminal Z-7 P20 M 3 Fuel control dial R-7
CK02 070 10 KOMTRAX terminal Z-7 P21 X 1 Fuel level sensor D-9
CM01 070 18 Machine monitor P-5 P22 DT 2 Hydraulic oil temperature sensor K-3
CM02 070 12 Machine monitor P-4 P23 DT 2 Air cleaner clogging sensor G-9
CM03 070 18 Machine monitor P-3 P24 X 2 Radiator coolant level sensor AJ-1
CM04 070 12 Machine monitor (disconnection) P-4 P25 AMP 3 F pump pressure sensor L-4
CM05 070 8 Machine monitor (for connection of camera) Q-6 P26 AMP 3 R pump pressure sensor K-3
CN1 DT 2 Injector #1 AK-9 P31 2 A/C sunshine sensor P-5
CN2 DT 2 Injector #2 AK-9 P44 DT 2 Engine oil level sensor AK-5
CN3 DT 2 Injector #3 AL-9 PAMB AMP 3 Ambient pressure sensor AM-9
CN4 DT 2 Injector #4 AN-7 PCV1 SUMITOMO 2 Supply pump #1 AJ-6
CN5 DT 2 Injector #5 AN-7 PCV2 SUMITOMO 2 Supply pump #2 AJ-6
CN6 DT 2 Injector #6 AN-7 PFUEL AMP 3 Common rail pressure sensor AL-5
CP01 AMP 81 Work equipment controller U-8 PIM SUMITOMO 3 Boost pressure sensor AN-6
CP02 AMP 40 Work equipment controller U-8 POIL SUMITOMO 2 Engine oil pressure switch AJ-6
D01 SWP 8 Assembled-type diode O-8 R01 Terminal 1 Battery relay (terminal E) B-6
D02 SWP 8 Assembled-type diode O-8 R02 Terminal 1 Battery relay (terminal BR) B-7
D03 SWP 8 Assembled-type diode P-9 R03A Terminal 1 Battery relay (terminal M) D-6
D10 M 2 Diode X-8 R03B Terminal 1 Battery relay (terminal M) D-6
D11 M 2 Diode Y-8 R04 Terminal 1 Battery relay (terminal B) D-7
EGR — 2 EGR valve (With EGR only) AJ-9 R05 Relay 5 Lamp relay U-9
F01 — — Fuse box V-9 R06 Relay 5 Starting motor cut relay (PPC lock) P-9
F04 L 2 Fusible link B-6 R07 Relay 5 Starting motor cut relay (personal code) P-9
F05 M 2 Fusible link E-2 R08 Relay 5 Horn relay W-9
G SUMITOMO 3 G sensor AJ-6 R10 Relay 5 Rear lamp relay [Rear lamp specification] U-9
H08 M 4 Intermediate connector Z-3 R12 Relay 5 Cab lamp relay [Cab lamp specification] W-9
H09 M 8 Intermediate connector AA-4 R15 Terminal 1 Electrical intake air heater relay (coil circuit) C-5
H14 M 4 Intermediate connector V-1 R16 Terminal 1 Electrical intake air heater relay (contact circuit) D-5
H15 S090 22 Intermediate connector V-1 R17 Terminal 1 Electrical intake air heater relay B-6
H16 S 12 Intermediate connector Z-3 R18 Relay 5 Auto preheat relay X-9
J01 J 20 Junction connector (Black) AA-7 R20 Relay 5 A/C blower relay T-8
J02 J 20 Junction connector (Black) Y-3 R21 Relay 5 A/C compressor relay T-8
J03 J 20 Junction connector (Green) Y-2 R23 Relay 5 Engine controller relay (1) W-9
J04 J 20 Junction connector (Green) Z-7 R24 Relay 5 Engine controller relay (2) X-9
J05 J 20 Junction connector (Pink) Y-8 RES D 2 Resistor AN-8
J06 J 20 Junction connector (Orange) Y-8 S02 SWP 6 Lamp switch S-7
J1939 D 3 CAN AM-9 S04 SWP 6 Swing lock switch S-7
JM01 Terminal 9 Junction connector AL-9 S05 SWP 6 Machine push up switch S-7
JM02 Terminal 9 Junction connector AL-9 S07 SWP 6 Rotary lamp switch [Rotary lamp specification] S-7
JM03 Terminal 9 Junction connector AN-8 S10 S090 2 Right knob switch R-6
K01 M 2 Pump (PC) resistor P-6 S11 Y090 2 Left knob switch W-1
K02 DT 3 CAN terminal resistance AL-5 S14 M 3 PPC oil pressure lock switch W-1
L01 DT 2 Working lamp (Boom) E-9 S15 SWP 6 Heated seat T-7
L02 DT 2 Right head lamp C-2 S21 — 12 Emergency pump drive switch P-9
L03 M 2 Room lamp AE-8 S22 — 6 Swing holding brake release switch P-9
L05 SWP 2 Rotary lamp [Rotary lamp specification/Arm crane specification] AF-9 S25 S090 16 Intermediate connector Q-8
L09 DT 2 Rear working lamp K-9 S30 S 8 Model selection connector U-8
L15 DT 2 Rotary lamp [Rotary lamp specification/Arm crane specification] AG-9 S50 DT 6 Electrical priming pump timer switch G-9
M01 DA 9 Radio X-1 SEGR D 4 EGR valve position sensor (With EGR only) AJ-9
M02 M 2 Speaker (Left) AH-8 SSW Starting switch R-6
M03 M 2 Speaker (Right) AG-9 T01 Terminal 1 Floor frame ground Y-3
M04 2 Cigarette lighter R-6 T02 Terminal 1 Cab ground AH-3
M05 M 6 Wiper motor P-3, AC-5 T03 M 1 Intermediate connector (radio ground) X-2
M06 KES 2 Window washer tank L-4 T03A Terminal 1 Radio ground X-2
M07 X 2 Horn (High tone) F-1 T04 Terminal 1 Revolving frame ground J-2
M08 X 2 Horn (Low tone) E-1 T05 Terminal 1 Revolving frame ground I-2
M09 M 2 Optional power supply connector (1) Z-3 T06 Terminal 1 Revolving frame ground I-2
M10 M 2 Optional power supply connector (2) AB-4 T07 Terminal 1 Revolving frame ground I-2
M11 M 4 DC/DC converter AB-5 T08 Terminal 1 Revolving frame ground D-2
M12 M 2 Optional power supply connector (12 V) AA-4 T09 Terminal 1 Revolving frame ground H-1
M13 M 2 12-V socket AB-5 T10 Terminal 1 Revolving frame ground H-1
M14 DT 2 Travel alarm J-2 T11 Terminal 1 Engine ground AM-4
M17 DT 2 Starting motor (terminal S and terminal R circuits) AI-1 T12 Terminal 1 Alternator ground AJ-1
M18 Terminal 1 Alternator (R) AK-1 TFUEL — 2 Fuel temperature sensor AM-5
M20 Terminal 1 Starting motor (B) AI-1 TIM — 2 Boost temperature sensor AM-9
M21 Terminal 1 Alternator (B) AL-1 TWTR — 2 Engine coolant temperature sensor AJ-1
M22 Terminal 1 Alternator (E) AK-1 V01 DT 2 PPC basic pressure lock solenoid valve V-5
M23 Terminal 1 Electrical intake air heater AK-9 V02 DT 2 Travel junction solenoid valve V-5
M24 X 2 Intermediate connector (pair with A73) F-9 V03 DT 2 Merge valve solenoid valve V-5
M34 X 1 A/C compressor H-9 V04 DT 2 Travel HI/LO solenoid valve V-4
M35 DT 2 Heated seat W-2 V05 DT 2 Swing holding brake solenoid valve V-4
M36 DT 2 Air suspension seat W-1 V06 DT 2 Machine push up solenoid valve V-4
M37 DT 2 Electrical priming pump AL-5 V07 DT 2 ATT return change solenoid valve V-3
M40 X 2 Front lamp (left) (if equipped) AD-8 V08 DT 2 2-stage relief solenoid valve V-4
M41 X 2 Front lamp (right) (if equipped) AC-7 V11 DT 2 PC-EPC valve L-6
N08 DT 12 Service connector V-9 V19 DT 2 LS-EPC valve L-7
N10 4 A/C unit T-8 V30 DT 2 ATT current control EPC valve [ATT specification] S-1
NE SUMITOMO 3 NE sensor AM-5 W03 M 2 Window rear limit switch AG-9
P01 AMP 3 Bucket curl PPC pressure sensor L-2
SEN04281-01
PC400, 450-8R
13
PC400, 450-8R 15
SEN04281-01

© 2011 KOMATSU
All Rights Reserved
16

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SEN04239-08

HYDRAULIC PC400 -8R

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN04239-08

00 Index and foreword SEN04240-08

10 Structure, function and maintenance standard SEN04245-05

20 Standard value table SEN04255-01

30 Testing and adjusting SEN04257-05

Troubleshooting of engine (S-mode) SEN04269-01

50 Disassembly and assembly SEN04270-05

90 Diagrams and drawings SEN04279-01

Foreword and general information SEN04242-00

10 Structure, function and maintenance standard

Hydraulic system, Part 3 SEN04251-01

20 Standard value table

30 Testing and adjusting

Inspecting locations of hydraulic drift of work equipment ............................................................ 50

Failure code [CA323] Inj #5 Open/Short Error ............................................................................ 60

Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 51

50 Disassembly and assembly

Undercarriage and frame SEN04274-03

90 Diagrams and drawings

PC400, 450(LC)-8R Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

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

a For tightening torque, see the precautions for

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

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