Beruflich Dokumente
Kultur Dokumente
HYDRAULIC PC400 -8
EXCAVATOR
PC400LC -8
PC450 -8
PC450LC -8
PC400- 70001
PC400LC- 70001
SERIAL NUMBERS and up
PC450- 70001
PC450LC- 70001
SEN02225-15
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02225-15 00 Index and foreword
01 Specification SEN02227-02
Specification and technical data SEN02228-02
40 Troubleshooting SEN02241-04
Failure code table and fuse locations SEN02646-03
General information on troubleshooting SEN02647-03
Troubleshooting by failure code (Display of code), Part 1 SEN02648-04
Troubleshooting by failure code (Display of code), Part 2 SEN02649-03
Troubleshooting by failure code (Display of code), Part 3 SEN02650-04
Troubleshooting of electrical system (E-mode) SEN02651-03
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02652-03
2 PC400, 450-8
00 Index and foreword SEN02225-15
PC400, 450-8 3
SEN02225-15 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN02225-15
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02226-02
Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02228-02
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 12
4 PC400, 450-8
00 Index and foreword SEN02225-15
PC400, 450-8 5
SEN02225-15 00 Index and foreword
40 Troubleshooting
Failure code table and fuse locations SEN02646-03
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 5
General information on troubleshooting SEN02647-03
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information contained in troubleshooting table............................................................................ 6
Phenomena looking like troubles and troubleshooting Nos. ....................................................... 8
Connection table for connector pin numbers............................................................................... 10
T- branch box and T- branch adapter table ................................................................................. 46
Troubleshooting by failure code (Display of code), Part 1 SEN02648-04
Failure code [989L00] Engine Controller Lock Caution 1............................................................ 3
Failure code [989M00] Engine Controller Lock Caution2............................................................ 4
Failure code [989N00] Engine Controller Lock Caution3 ............................................................ 5
Failure code [AA10NX] Air cleaner Clogging .............................................................................. 6
Failure code [AB00KE] Charge Voltage Low............................................................................... 8
Failure code [B@BAZG] Eng Oil Press. Low .............................................................................. 10
Failure code [B@BAZK] Eng Oil Level Low ................................................................................ 12
Failure code [B@BCNS] Eng. Water Overheat........................................................................... 14
Failure code [B@BCZK] Eng Water Level Low........................................................................... 16
Failure code [B@HANS] Hydr Oil Overheat................................................................................ 18
Failure code [CA111] ECM Critical Internal Failure ..................................................................... 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 21
Failure code [CA122] Chg Air Press Sensor High Error.............................................................. 22
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 24
Failure code [CA131] Throttle Sensor High Error........................................................................ 26
Failure code [CA132] Throttle Sensor Low Error ........................................................................ 28
Failure code [CA135] Eng Oil Press Sensor High Error.............................................................. 30
Failure code [CA141] Eng Oil Press Sensor Low Error............................................................... 32
Failure code [CA141] Eng Oil Press Sensor Low Error............................................................... 33
Failure code [CA145] Coolant Temp Sens Low Error.................................................................. 35
Failure code [CA153] Chg Air Temp Sensor High Error .............................................................. 37
Failure code [CA154] Chg Air Temp Sensor Low Error............................................................... 39
Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 41
Failure code [CA221] Ambient Press Sens High Error................................................................ 43
Failure code [CA222] Ambient Press Sens Low Error ................................................................ 45
Failure code [CA227] Sens Supply 2 Volt High Error .................................................................. 47
Failure code [CA234] Eng Overspeed......................................................................................... 48
Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................. 49
Failure code [CA263] Fuel Temp Sensor High Error ................................................................... 50
6 PC400, 450-8
00 Index and foreword SEN02225-15
PC400, 450-8 7
SEN02225-15 00 Index and foreword
8 PC400, 450-8
00 Index and foreword SEN02225-15
PC400, 450-8 9
SEN02225-15 00 Index and foreword
10 PC400, 450-8
00 Index and foreword SEN02225-15
PC400, 450-8 11
SEN02225-15
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 02-17 (01)
12
SEN02226-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02226-02 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 PC400, 450-8
00 Index and foreword SEN02226-02
PC400, 450-8 3
SEN02226-02 00 Index and foreword
4 PC400, 450-8
00 Index and foreword SEN02226-02
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC400, 450-8 5
SEN02226-02 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 PC400, 450-8
00 Index and foreword SEN02226-02
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.
01. Specification
This section explains the specifications of the machine.
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.
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.
PC400, 450-8 7
SEN02226-02 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
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.
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.
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, 450-8
00 Index and foreword SEN02226-02
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC400, 450-8 9
SEN02226-02 00 Index and foreword
10 PC400, 450-8
00 Index and foreword SEN02226-02
PC400, 450-8 11
SEN02226-02 00 Index and foreword
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.
12 PC400, 450-8
00 Index and foreword SEN02226-02
PC400, 450-8 13
SEN02226-02 00 Index and foreword
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, 450-8
00 Index and foreword SEN02226-02
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, 450-8 15
SEN02226-02 00 Index and foreword
16 PC400, 450-8
00 Index and foreword SEN02226-02
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.
PC400, 450-8 17
SEN02226-02 00 Index and foreword
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.
18 PC400, 450-8
00 Index and foreword SEN02226-02
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, 450-8 19
SEN02226-02 00 Index and foreword
20 PC400, 450-8
00 Index and foreword SEN02226-02
q 114 engine
q 107 engine
PC400, 450-8 21
SEN02226-02 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC400, 450-8
00 Index and foreword SEN02226-02
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.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC400, 450-8 23
SEN02226-02 00 Index and foreword
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
24 PC400, 450-8
00 Index and foreword SEN02226-02
(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.
(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, 450-8 25
SEN02226-02 00 Index and foreword
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, 450-8
00 Index and foreword SEN02226-02
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.
PC400, 450-8 27
SEN02226-02 00 Index and foreword
28 PC400, 450-8
00 Index and foreword SEN02226-02
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, 450-8 29
SEN02226-02 00 Index and foreword
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
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 PC400, 450-8
00 Index and foreword SEN02226-02
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal 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-
onal portion at the male end. (Fig. 13)
PC400, 450-8 31
SEN02226-02 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 PC400, 450-8
00 Index and foreword SEN02226-02
PC400, 450-8 33
SEN02226-02 00 Index and foreword
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.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 PC400, 450-8
00 Index and foreword SEN02226-02
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC400, 450-8 35
SEN02226-02 00 Index and foreword
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
36 PC400, 450-8
00 Index and foreword SEN02226-02
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
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, 450-8 37
SEN02226-02 00 Index and foreword
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, 450-8
00 Index and foreword SEN02226-02
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, 450-8 39
SEN02226-02 00 Index and foreword
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
40 PC400, 450-8
00 Index and foreword SEN02226-02
PC400, 450-8 41
SEN02226-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN02228-02
PC400LC-8
SEN02228-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
01 Specification
Specification and technical data
PC400, 450-8 1
SEN02228-02 01 Specification
2 PC400, 450-8
01 Specification SEN02228-02
Working range
PC400, 450-8 3
SEN02228-02 01 Specification
Specifications
PC400-8, PC400LC-8
Machine model PC400-8 PC400LC-8
4 PC400, 450-8
01 Specification SEN02228-02
PC400, 450-8 5
SEN02228-02 01 Specification
PC450-8, PC450LC-8
Travel speed km/h Lo: 3.0 Mi: 4.2 Hi: 5.5 Lo: 3.0 Mi: 4.2 Hi: 5.5
Gradability degree 35 35
Ground pressure (Standard shoe) kPa {kg/cm2} 82.9 {0.85} 78.1 {0.80}
6 PC400, 450-8
01 Specification SEN02228-02
Model SAA6D125E-5
4-cycle, water-cooled in-line, direct injection with turbo-
Type
charger and air cooled 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 {350/1,900}
Performance
Type
ton ton ton
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 oil cooler CF40-1 (Air cooled)
*1: Cushion is provided on the head side
*2: Cushion is provided on the bottom side
PC400, 450-8 7
SEN02228-02 01 Specification
Weight table
PC400-8, PC400LC-8
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Operator's seat 35 35
8 PC400, 450-8
01 Specification SEN02228-02
Unit: kg
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, 450-8 9
SEN02228-02 01 Specification
PC450-8, PC450LC-8
Unit: kg
Operator's seat 35 35
10 PC400, 450-8
01 Specification SEN02228-02
Unit: kg
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, 450-8 11
SEN02228-02 01 Specification
Unit: l
PC400-8/PC400LC-8,PC450-8/PC450LC-8
Reservoir
Specified Refill
Engine oil pan 46 37
Swing machinery case 20 20
Final drive case
10.5 10.5
(each sides)
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.
12 PC400, 450-8
01 Specification SEN02228-02
PC400, 450-8 13
SEN02228-02 01 Specification
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
14
SEN02230-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02230-00 10 Structure, function and maintenance standard
2 PC400, 450-8
10 Structure, function and maintenance standard SEN02230-00
Specifications
Radiator: Aluminum wave type, 4 rows
Oil cooler: CF40-1
PC400, 450-8 3
SEN02230-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
4
SEN02231-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02231-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02231-00
Swing circle 1
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, 450-8 3
SEN02231-00 10 Structure, function and maintenance standard
Swing machinery 1
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02231-00
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
PC400, 450-8 5
SEN02231-00 10 Structure, function and maintenance standard
Final drive 1
Specifications
Reduction ratio:
– 10 + 98 × 18 + 98 = –68.600
10 18
6 PC400, 450-8
10 Structure, function and maintenance standard SEN02231-00
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun gear Standard clearance Clearance limit
14 and No. 1 planetary gear 0.15 – 0.54 1.10
Backlash between No. 1 planetary
15 gear and ring gear
0.18 – 0.66 1.30
PC400, 450-8 7
SEN02231-00 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip
355 343
Build-up welding
2 Thickness of tooth root 20.8 14.8
for rebuilding or
3 Width of tooth 90 87 replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth
4 Wear of tooth shape shape)
8 PC400, 450-8
10 Structure, function and maintenance standard SEN02231-00
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, 450-8 9
SEN02231-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
10
SEN02232-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02232-00 10 Structure, function and maintenance standard
2 PC400, 450-8
10 Structure, function and maintenance standard SEN02232-00
Standard shoe
Models
PC400-8 PC400LC-8 PC450-8 PC450LC-8
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
No. Check Item Criteria Remedy
Standard size Tolerance Rapair limit
PC400, 450-8 3
SEN02232-00 10 Structure, function and maintenance standard
Idler 1
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02232-00
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
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, 450-8 5
SEN02232-00 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of flange
179 —
2 Outside diameter of tread 152 138
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, 450-8
10 Structure, function and maintenance standard SEN02232-00
Track roller 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Rapair limit
1 Outside diameter of outer flange
240 —
Outside diameter of inner flange
2 (Double flange)
237 —
PC400, 450-8 7
SEN02232-00 10 Structure, function and maintenance standard
Track shoe 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
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
Standard size Repair limit
4 Link height
129 119
Repair or replace
Thickness of link metal (bushing
5 press-fitting portion)
34.5 24.5
8 PC400, 450-8
10 Structure, function and maintenance standard SEN02232-00
Unit: mm
No. Check Item Criteria Remedy
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
Tolerance
Standard size Standard clearance
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
Standard size Standard clearance
25 Clearance between master pin and Shaft Hole
(*) bushing –0.2 +0.915
47 0.615 – 1.315
–0.4 +0.415
PC400, 450-8 9
SEN02232-00 10 Structure, function and maintenance standard
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
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
Standard size Repair limit
8 Thickness
50 35
10 PC400, 450-8
10 Structure, function and maintenance standard SEN02232-00
PC400, 450-8 11
SEN02232-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
12
SEN02233-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 3
SEN02233-00 10 Structure, function and maintenance standard
Bypass valve
Set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 5
SEN02233-00 10 Structure, function and maintenance standard
Hydraulic pump 1
Type: HPV160+160 (190)
6 PC400, 450-8
10 Structure, function and maintenance standard SEN02233-00
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
EPC valve and variable volume valve.
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, 450-8 7
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
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, 450-8 9
SEN02233-00 10 Structure, function and maintenance standard
Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
10 PC400, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 11
SEN02233-00 10 Structure, function and maintenance standard
1. LS valve
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
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, 450-8 13
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 15
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
2. PC valve
PC400, 450-8 17
SEN02233-00 10 Structure, function and maintenance standard
Operation
(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, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 19
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 21
SEN02233-00 10 Structure, function and maintenance standard
(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, 450-8
10 Structure, function and maintenance standard SEN02233-00
PC400, 450-8 23
SEN02233-00 10 Structure, function and maintenance standard
2) As the emergency pump drive switch is turned on due to failure on the pump controller
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
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, 450-8 25
SEN02233-00 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02233-00
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, 450-8 27
SEN02233-00 10 Structure, function and maintenance standard
28 PC400, 450-8
10 Structure, function and maintenance standard SEN02233-00
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, 450-8 29
SEN02233-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
30
SEN02234-04
PC400LC-8
SEN02234-01
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400, 450-8 1
SEN02234-04 10 Structure, function and maintenance standard
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 prevention 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 selector 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
P-4: From service 1 and PPC valves
P-5: From service 2 and PPC valves
P-6: From service 2 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, 450-8
10 Structure, function and maintenance standard SEN02234-04
General view
PC400, 450-8 3
SEN02234-04 10 Structure, function and maintenance standard
Sectional view
(1/5)
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
Unit: mm
PC400, 450-8 5
SEN02234-04 10 Structure, function and maintenance standard
(2/5)
6 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
Unit: mm
PC400, 450-8 7
SEN02234-04 10 Structure, function and maintenance standard
(3/5)
8 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
1. Unload valve
2. Safety valve (Boom raise)
3. Main relief valve
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)
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H)
Unit: mm
PC400, 450-8 9
SEN02234-04 10 Structure, function and maintenance standard
(4/5)
10 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
1. Return spring
2. Merge-divider valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divider valve (Main)
6. Return spring
Boom valve
7. Drift prevention 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)
Bucket valve
23. LS shuttle valve
24. Pressure compensation valve (Curl)
25. Spool
26. Suction safety valve (Curl)
27. Safety-suction valve (Dump)
28. Pressure compensation valve (Dump)
Unit: mm
No. Check item Criteria Remedy
Standardsize Repairlimit
Free length x
Installed
Outside Installed load Free length Installed load
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
30 Check valve spring 70.9 × 18.0 56.0 —
{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
32 Check valve spring 33.0 × 12.0 26.0 —
{3.6 kg} {2.88 kg}
13.7 N 11.0 N
33 Check valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}
5.9 N 4.71 N
34 Check valve spring 31.5 × 10.3 19.5 —
{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, 450-8 11
SEN02234-04 10 Structure, function and maintenance standard
(5/5)
12 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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
14. LS shuttle valve
15. Pressure compensation valve
16. Spool
17. Safety-suction valve
18. Unload valve
19. Main relief valve
20. LS bypass valve
PC400, 450-8 13
SEN02234-04 10 Structure, function and maintenance standard
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
controll
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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) (dPLS) is lower than the set pressure of the LS
and control valve outlet port LS pressure (PLS) valve (when the actuator load pressure is high).If
(load pressure of actuator) is constant. 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 to ward the minimum
position.
PC400, 450-8 15
SEN02234-04 10 Structure, function and maintenance standard
16 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
3. System diagram
PC400, 450-8 17
SEN02234-04 10 Structure, function and maintenance standard
18 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
PC400, 450-8 19
SEN02234-04 10 Structure, function and maintenance standard
Unload valve
1. When the unload valve is actuating
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 q When this pressure becomes larger than the
{0 kg/cm2}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pumpdischarge 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, 450-8
10 Structure, function and maintenance standard SEN02234-04
PC400, 450-8 21
SEN02234-04 10 Structure, function and maintenance standard
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (spool
meter-in downstream pressure) of pressure
compensation valve (3) and leads to LS shuttle
valve (7) as the LS pressure.
q Connected to actuator port (B) through valve (4),
and makes LS pressure C actuator load 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 pressure rises to reach the load
pressure of port (B), check valve (5) opens and
the pressurized oil flows.
22 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
LS bypass valve
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
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 therising 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, 450-8 23
SEN02234-04 10 Structure, function and maintenance standard
24 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 25
SEN02234-04 10 Structure, function and maintenance standard
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-
cordingto the opening area ratio.
q If area ratio = 1 or over:The spool meter-in down-
stream pressure will be greater than the maxi-
mum 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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 27
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
1. Hydraulic pump
2. Boom spool
3. Pressure compensation valve
4. Safety-suction valve
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, 450-8 29
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
1. Hydraulic pump
2. Arm spool
3. Pressure compensation valve
4. Safety-suction valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
q During arm digging,regeneration circuit provided q If the cylinder head pressure is higher than the
from the cylinder head to the bottom increases bottom pressure, pressurized oil (A) from the cyl-
the cylinder speed as the cylinder flow involves inder head flows to drain circuit (B) from the
the pump delivery plus regenerated flow. notch of arm 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, 450-8 31
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
Merge-divider valve
1. When flows from the pumps merge [if pilot pressure (PS) is OFF]
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 dividesLS 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, 450-8 33
SEN02234-04 10 Structure, function and maintenance standard
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 oildischarged 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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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 workvalves while q Since pilot pressure (BP) is OFF, piston (3) is
the swinging and work equipment are in com- pressed 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).
PC400, 450-8 35
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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) Pressure [(fd area Å~ P2 pres-
q Valve (7) is pressed to the closing direction of sure) = force of spring (8) + (fd area Å~ 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 stroke end.
{0 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 [(?d area Å~ P2 pres- ducing the engine horsepower loss.
sure) = force of spring (8) + (?d area Å~ PR pres- q When pressure (PR) rises above the set pres-
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, 450-8 37
SEN02234-04 10 Structure, function and maintenance standard
38 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 39
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 41
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
Function
q This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) and the
boom from lowering under its weight while the
boom lever is not operated.
Operation
q When the boom is raised, pressurized oil from
the control valve works on the ring-shaped area
(S)[= ?(d1) area ? ?(d2) area] caused by the 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, 450-8 43
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 45
SEN02234-04 10 Structure, function and maintenance standard
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) [= ?(d1) area ? ?(d2) area] caused by
the difference between the outside diameter (d1)
of poppet (5) and the seat diameter (d2) to move
it to the left.
q Contracts spring (4) and poppet (5) moves to the
left.
q As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.
46 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 47
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 49
SEN02234-04 10 Structure, function and maintenance standard
Function
q When arm is set to out, large volume of oil re- q Reduces this pressure loss.
turns from the cylinder bottom.
Operation
q When arm is set to out, pilot piston (1) is pushed q Or (?d2 pressure receiving force > ?d1 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 [?d2 area (S2) (seat
diameter area)] on the side of port (A) increases
by the sum of the pressure receiving force of
pressure receiving portion[?d1 area (S1)] on the
chamber (b) side of valve (2) and the spring
force.
50 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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, 450-8 51
SEN02234-04 10 Structure, function and maintenance standard
52 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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.
PC400, 450-8 53
SEN02234-04 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
PC400, 450-8 55
SEN02234-04 10 Structure, function and maintenance standard
56 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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 Å~ A1 = P Å~ A2 + LS(A2 ? 1) + F q Force that presses valve (1) to the left is re-
duced.
A1: Area of ?d1 q A state is reached where the area ratio has be-
A2: Area of ?d2 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, 450-8 57
SEN02234-04 10 Structure, function and maintenance standard
ACC: To accumulator
ATT: To attachment
P1: From attachment selector solenoid valve
T: To hydraulic tank
TS: To hydraulic tank
V: To control valve
1. Spool
2. Spring
Unit: mm
58 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
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
1. When attachment other than breaker is in- 2. When breaker is installed
stalled q Pilot pressure (P1) from the attachment circuit
q Spool (1) is pressed to the left by the force of selector solenoid valve compresses spring (2),
spring (2). moving spool (1) rightward to the stroke end.
q Ports (ATT) and (V) are interconnected and q Ports (ATT) and (V) are shut off and ports (ATT)
ports (ATT) and (T) are shut off. Attachment is and (T) are interconnected.
thus interconnected to the control valve. q Pressurized oil returning from the breaker re-
turns directly to the hydraulic tank through port
(T) without passing through the control valve.
PC400, 450-8 59
SEN02234-04 10 Structure, function and maintenance standard
Holding valve
(For the boom and arm)
60 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
1. Pilot spool
2. Spool (1st stage spool)
3. Spring (2nd stage spool)
4. Safety valve
5. Check valve
6. Spring
Unit: mm
PC400, 450-8 61
SEN02234-04 10 Structure, function and maintenance standard
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
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, 450-8
10 Structure, function and maintenance standard SEN02234-04
PC400, 450-8 63
SEN02234-04 10 Structure, function and maintenance standard
64 PC400, 450-8
10 Structure, function and maintenance standard SEN02234-04
PC400, 450-8 65
SEN02234-04 10 Structure, function and maintenance standard
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 08-11
66
SEN02235-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02235-02 10 Structure, function and maintenance standard
Valve control 1
2 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 3
SEN02235-02 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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
No. Check item Criteria Remedy
Standard size Repair limit
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, 450-8 5
SEN02235-02 10 Structure, function and maintenance standard
6 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 7
SEN02235-02 10 Structure, function and maintenance standard
8 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 9
SEN02235-02 10 Structure, function and maintenance standard
10 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
11 Centering spring Outside diameter length load load
108 N 86.3 N If damaged or
48.6 × 15.5 32.5 —
{11.0 kg} {8.8 kg} deformed, replace
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, 450-8 11
SEN02235-02 10 Structure, function and maintenance standard
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
the stroke of the control lever.
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.
12 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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.
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-
ti o n , t h e hi g h e r o ne o f t h e P P C o u tp u 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, 450-8 13
SEN02235-02 10 Structure, function and maintenance standard
Operation
1) When in neutral
14 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 15
SEN02235-02 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02235-02
4) When counter-rotated
a The illustration shows the circuit for travelling left reverse and right forward.
PC400, 450-8 17
SEN02235-02 10 Structure, function and maintenance standard
a For the details of operation, see the paragraph of “Work equipment swing PPC valve.”
18 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Block
7. Body
8. EPC valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
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, 450-8 19
SEN02235-02 10 Structure, function and maintenance standard
Solenoid valve 1
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up and travel junc-
tion solenoid valves
20 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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, 450-8 21
SEN02235-02 10 Structure, function and maintenance standard
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, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 23
SEN02235-02 10 Structure, function and maintenance standard
Structure
General view
24 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Function
This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder
breaks.
PC400, 450-8 25
SEN02235-02 10 Structure, function and maintenance standard
26 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Load at Load at
Installation
x Outside installed Free length installed
length
1 Check valve spring diameter height height
Replace
12.74 N 10.2 N (Replace spring
20.8 × 12.2 13.5 —
{1.3 kg} {1.0 kg} if damaged or
58.8 N 47.0 N deformed as
2 Spool return spring 41.1 × 9.6 35.0 — well)
{6.0 kg} {4.8 kg}
41.85 × 78.4 N 62.7 N
3 Spool return spring 41.0 —
25.8 {8.0 kg} {6.4 kg}
PC400, 450-8 27
SEN02235-02 10 Structure, function and maintenance standard
Operation
When work equipment is in NEUTRAL When the pressurized oil flows from the
When there is no damage in the piping control valve to the work equipment cylin-
1. Holding pressure of the work equipment cylin- der
der is led from port (CY) to chamber (b), and it When there is no damage in the piping
closes check valve (5). 1. The pressurized oil which is led from the con-
2. The pilot pressure which is led from PPC valve trol valve to chamber (a) becomes higher than
to port (PI) is 0 MPa{0 kg/cm 2 } when work the combined force of the pressure of chamber
equipment is in NEUTRAL.
(b) of work equipment cylinder circuit and
3. Spool (1) is pressed to the left by the force of spring (6).
springs (2) and (3).
2. Check valve (5) opens, and chamber (a) and
4. Chamber (a) and chamber (b) are disconnected.
chamber (b) are connected.
5. The pressurized oil does not flow from control
valve to work equipment cylinder. The work 3. The pressurized oil flows from the control valve
equipment cylinder is held. to the work equipment cylinder.
6. When the pressure inside the work equipment
cylinder is abnormally high, holding pressure of When there is a damage in the piping
the work equipment cylinder operates safety 1. When there is a damage in the piping (A)
valve (4). between the control valve and the work equip-
7. Chambers (b) of anti-drop valves on the right ment cylinder, the pressurized oil of chamber
and left are interconnected at port (PCY). (a) leaks through the damaged part to the out-
8. The pressures of chambers (b) are the same side.
even when there is a difference of leakage 2. The pressure of chamber (a) drops. The pres-
amount between the anti-drop valves on the
sure of chamber (a) becomes lower than the
right and left.
When there is a damage in the piping combined force of the pressure of chamber (b)
and spring (6).
1. When there is a damage in the piping (A)
between the control valve and the work equip- 3. Check valve (5) closes, and chamber (a) and
ment cylinder, chamber (a) and chamber (b) chamber (b) are disconnected.
are disconnected. 4. The pressure of the work equipment is held to
2. The pressure of the work equipment is held to prevent the work equipment from sudden low-
prevent the work equipment from sudden low- ering.
ering.
28 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 29
SEN02235-02 10 Structure, function and maintenance standard
Structure
General view
30 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Function
This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder
breaks.
PC400, 450-8 31
SEN02235-02 10 Structure, function and maintenance standard
32 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Load at Load at
Installation
x Outside installed Free length installed
length
1 Check valve spring diameter height height
Replace
12.74 N 10.2 N (Replace spring
20.8 × 12.2 13.5 —
{1.3 kg} {1.0 kg} if damaged or
58.8 N 47.0 N deformed as
2 Spool return spring 41.1 × 9.6 35.0 — well)
{6.0 kg} {4.8 kg}
41.85 × 78.4 N 62.7 N
3 Spool return spring 41.0 —
25.8 {8.0 kg} {6.4 kg}
PC400, 450-8 33
SEN02235-02 10 Structure, function and maintenance standard
Operation
When work equipment is in NEUTRAL When the pressurized oil flows from the
When there is no damage in the piping control valve to the work equipment cylin-
1. Holding pressure of the work equipment cylin- der
der is led from port (CY) to chamber (b), and it When there is no damage in the piping
closes check valve (5). 1. The pressurized oil which is led from the con-
2. The pilot pressure which is led from PPC valve trol valve to chamber (a) becomes higher than
to port (PI) is 0 MPa{0 kg/cm 2 } when work the combined force of the pressure of chamber
equipment is in NEUTRAL. (b) of work equipment cylinder circuit and
3. Spool (1) is pressed to the left by the force of spring (6).
springs (2) and (3). 2. Check valve (5) opens, and chamber (a) and
4. Chamber (a) and chamber (b) are discon- chamber (b) are connected.
nected. 3. The pressurized oil flows from the control valve
5. The pressurized oil does not flow from control to the work equipment cylinder.
valve to work equipment cylinder. The work
equipment cylinder is held. When there is a damage in the piping
6. When the pressure inside the work equipment 1. When there is a damage in the piping (A)
cylinder is abnormally high, holding pressure of between the control valve and the work equip-
the work equipment cylinder operates safety ment cylinder, the pressurized oil of chamber
valve (4). (a) leaks through the damaged part to the out-
side.
When there is a damage in the piping 2. The pressure of chamber (a) drops. The pres-
1. When there is a damage in the piping (A) sure of chamber (a) becomes lower than the
between the control valve and the work equip- combined force of the pressure of chamber (b)
ment cylinder, chamber (a) and chamber (b) and spring (6).
are disconnected. 3. Check valve (5) closes, and chamber (a) and
2. The pressure of the work equipment is held to chamber (b) are disconnected.
prevent the work equipment from sudden low- 4. The pressure of the work equipment is held to
ering. prevent the work equipment from sudden low-
ering.
34 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 35
SEN02235-02 10 Structure, function and maintenance standard
36 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
For breaker
PC400, 450-8 37
SEN02235-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor and Standard size Standard clearance Clearance limit
6 shaft
Replace
80 — —
38 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Travel motor 1
Type: KMV200ADT-2
PC400, 450-8 39
SEN02235-02 10 Structure, function and maintenance standard
40 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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
No. Check item Criteria Remedy
Standard size Repair limit
Free length × Installed Installed Installed
Free length
21 Spool return spring Outside diameter length load load
427 N 341 N If damaged or
62.5 × 32.0 42.0 —
{43.5 kg} {34.8 kg} deformed, replace
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, 450-8 41
SEN02235-02 10 Structure, function and maintenance standard
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
42 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 43
SEN02235-02 10 Structure, function and maintenance standard
44 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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, 450-8 45
SEN02235-02 10 Structure, function and maintenance standard
46 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 47
SEN02235-02 10 Structure, function and maintenance standard
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.
48 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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.
PC400, 450-8 49
SEN02235-02 10 Structure, function and maintenance standard
50 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Swing motor 1
Type: KMF230ABE-5
PC400, 450-8 51
SEN02235-02 10 Structure, function and maintenance standard
52 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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
No. Check item Criteria Remedy
Basic dimensions Repair limit
Free length × Installed Installed Installed
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, 450-8 53
SEN02235-02 10 Structure, function and maintenance standard
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.
54 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 55
SEN02235-02 10 Structure, function and maintenance standard
56 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
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)
PC400, 450-8 57
SEN02235-02 10 Structure, function and maintenance standard
58 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
PC400, 450-8 59
SEN02235-02 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
60 PC400, 450-8
10 Structure, function and maintenance standard SEN02235-02
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
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, 450-8 61
SEN02235-02
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 02-17 (01)
62
SEN02236-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02236-00 10 Structure, function and maintenance standard
Work equipment 1
2 PC400, 450-8
10 Structure, function and maintenance standard SEN02236-00
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
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
PC400, 450-8 3
SEN02236-00 10 Structure, function and maintenance standard
Dimensions of components 1
1. Dimension of arm
4 PC400, 450-8
10 Structure, function and maintenance standard SEN02236-00
Unit: mm
PC400-8 PC450-8
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
PC400, 450-8 5
SEN02236-00 10 Structure, function and maintenance standard
2. Dimension of bucket
6 PC400, 450-8
10 Structure, function and maintenance standard SEN02236-00
Unit: mm
PC400-8, PC400LC-8 PC450-8, PC450LC-8
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, 450-8 7
SEN02236-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
8
SEN02237-00
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02237-00 10 Structure, function and maintenance standard
2 PC400, 450-8
10 Structure, function and maintenance standard SEN02237-00
PC400, 450-8 3
SEN02237-00
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 04-07 (01)
4
SEN02238-03
PC400LC-8
SEN02238-02
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
10 Structure,function and
maintenance standard
Electrical system
PC400, 450-8 1
SEN02238-03 10 Structure,function and maintenance standard
Engine control
2 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 3
SEN02238-03 10 Structure,function and maintenance standard
Component
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, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 5
SEN02238-03 10 Structure,function and maintenance standard
Engine controller
*: Never connect to NC, or malfunctions or failures *: Never connect to NC, or malfunctions or failures
will occure. will occure.
6 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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 (+5 V) 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 occure.
48 NC (*) D
PWMOUTPUT
CN-CE02 49 D
(Power train relay output)
Input/out- 50 NC (*) D
Pin No. Signal name
put
1 NC (*) B *: Never connect to NC, or malfunctions or failures
2 NC (*) B will occure.
3 NC (*) B
4 NC (*) B CN-CE03
5 NC (*) B Input/out-
Pin No. Signal name
6 NC (*) B put
1 GND C
7 NC (*) B
2 NC (*) C
8 NC (*) B
Electric power supply
9 Fuel control dial (+) B 3 A
(+24 V constantly)
10 NC (*) E 4 NC (*) A
11 NC (*) B
12 NC (*) B *: Never connect to NC, or malfunctions or failures
will occure.
*: Never connect to NC, or malfunctions or failures
will occure.
PC400, 450-8 7
SEN02238-03 10 Structure,function and maintenance standard
Rotation sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
8 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
1. Connector
2. Pressure import port
1. O-ring
2. Sensor
3. Connector
PC400, 450-8 9
SEN02238-03 10 Structure,function and maintenance standard
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
10 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
1. Core
2. O-ring
3. Sensor
4. Connector
PC400, 450-8 11
SEN02238-03 10 Structure,function and maintenance standard
1. Connector
2. Bracket
3. Float
4. Switch
12 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Control function
Auto-deceleration function
Self-diagnosis function
PC400, 450-8 13
SEN02238-03 10 Structure,function and maintenance standard
14 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 15
SEN02238-03 10 Structure,function and maintenance standard
16 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 17
SEN02238-03 10 Structure,function and maintenance standard
B and L modes
Mode B L
Partial output point 82 % 61 %
18 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 19
SEN02238-03 10 Structure,function and maintenance standard
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.
20 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
2) Cut-off function
q This function increases PC-EPC current
(J) to reduce the flow rate in the relief
state, improving fuel consumption.
PC400, 450-8 21
SEN02238-03 10 Structure,function and maintenance standard
Function
q The power maximizing function allows the oper-
ator to increases power for a certain time by op-
erating 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.
22 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 23
SEN02238-03 10 Structure,function and maintenance standard
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
operate any lever.
When any control lever is operated
q If you operate any control lever while the engine
speed is kept at the deceleration operation level,
the engine speed instantly rises to the level set
with the fuel control dial.
24 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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 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.
PC400, 450-8 25
SEN02238-03 10 Structure,function and maintenance standard
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
26 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Function
The swing lock and swing brake function are provid-
ed as a swing control function.
PC400, 450-8 27
SEN02238-03 10 Structure,function and maintenance standard
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 brake function (auto- relief pressure rises from 34.8 MPa
matic) is used to prevent hydraulic drift {355kg/cm2} to 37.2 MPa {380 kg/cm2}. If
after the machine stops swinging. the work equipment is relieved under this
q Operation of swing lock switch and swing condition, the hydraulic oil temperature
lock/ swing 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.
28 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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.
PC400, 450-8 29
SEN02238-03 10 Structure,function and maintenance standard
30 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Function
q This function is available only with the attach-
ment specification.
q The function acts as follows according to the flow
command and working mode from the monitor.
1) It throttles the attachment PPC pressure and
controls the flow when the pedal is
depressed fully.
2) In B mode and the other modes, it switches
to attachment single acting (B) or double
acting (other modes).
PC400, 450-8 31
SEN02238-03 10 Structure,function and maintenance standard
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.
32 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
1. Sensor
2. Connector
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.
PC400, 450-8 33
SEN02238-03 10 Structure,function and maintenance standard
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.
34 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
4) Pump controller
PC400, 450-8 35
SEN02238-03 10 Structure,function and maintenance standard
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_5 V _0 output 60 Start switch) Input
10 NC (*) Input 61 NC (*) —
11 NC (*) — 62 NC(*) Input
12 NC (*) — 63 NC (*) -—
13 NC (*) — 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 (*) —
68 R pump pressure sensor Input
18 GND_SIG_A Input
19 Swing lock switch Input
69 NC (*) —
20 NC (*) — 70 NC (*) —
21 Model select 2 Input
71 NC (*) —
22 NC (*) — 72 NC (*) —
73 Bucket curl pilot sensor Input
23 NC (*) —
24 PWR_CTR_KEY Input
74 Overload pressure sensor —
75 Wiper limit switch (P) Input
25 NC (*) —
26 NC (*) — 76 NC (*) —
77 Machin se;ect 3 Input
27 NC (*) —
28 NC (*) — 78 Overload caution enable switch —
79 Start switch (ACC) Input
29 Hydraulic- oil temperature Input
30 NC (*) — 80 NC (*) —
31 NC (*) — 81 GND_SIG_D —
32 NC (*) — *:Never connect to NC or malfunctions or failures
33 NC (*) — will occur
34 Bucket dump pressure switch Input
35 NC (*) —
36 Travel steering switch Input
37 GND_SIG_D) —
38 Swing prolix switch Input
39 Model select 5 Input
40 Model 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(*) —
36 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
CN-C02
Input/out-
Pin No. Signal name
put
82 NC (*) —
83 NC (*) —
84 NC (*) —
85 NC (*) —
86 Att circuit change solenoid output
87 Travel speed solenoid output
88 NC(*) output
89 NC (*) —
90 NC (*) —
91 NC (*) —
92 NC (*) —
93 NC (*) —
94 NC (*) —
95 NC (*) output
96 PC-EPC (F) output
97 Att flux limit epc outputt
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 Solednoid power supply Input
117 GND_ACT Input
118 Solednoid power supply Input
119 Wiper motor(+) output
120 GND_AC Input
121 Solenoid power supply Input
PC400, 450-8 37
SEN02238-03 10 Structure,function and maintenance standard
Monitor system
38 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and the functions to turn on/off electrical.
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.
PC400, 450-8 39
SEN02238-03 10 Structure,function and maintenance standard
40 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
CN-CM05
Input/out-
Pin No. Signal name
put
1 Electric power supply for camera Output
2 Camera NTSC signal input 1 Input
3 Camera NTSC signal input 2 Input
4 Camera NTSC signal input 3 Input
5 Electric power supply GND for camera —
6 Camera signal GND1 —
7 Camera signal GND2 —
8 Camera signal GND3 —
PC400, 450-8 41
SEN02238-03 10 Structure,function and maintenance standard
42 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 43
SEN02238-03 10 Structure,function and maintenance standard
Engine coolant
temperature
Hydraulic oil tem-
perature
Fuel level See gauge display on next page.
PTO oil tempera-
ture
Engine oil pres-
sure
44 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
PC400, 450-8 45
SEN02238-03 10 Structure,function and maintenance standard
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the exceeded items of the checks before starting or maintenance interval lights up, the display of the hy-
draulic oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols
are displayed.
46 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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-
ONio OFF Displays operating condition.
tioner/Heater
INT ON OFF
Wiper Displays set condition.
Monitor
Working
P, E, L, B, ATT Displays set mode.
mode
Lo Mi Hi
Travel speed Displays operating condition.
Auto-decel-
ONio OFF Displays operating condition.
eration
Displays time.
12-hour displayio 24-hour
Clock Clock (Changes to service meter if
display
F4 is depressed.)
PC400, 450-8 47
SEN02238-03 10 Structure,function and maintenance standard
Switches
48 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Switch
Symbol Item Function
power
Display No. 1 and No. 2 cam- Displays No. 1 and No. 2 camera screens
F4
era screens simultaneously.
PC400, 450-8 49
SEN02238-03 10 Structure,function and maintenance standard
Display Setting
Crawler symbol + Lo Low speed (default)
50 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 51
SEN02238-03 10 Structure,function and maintenance standard
52 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 53
SEN02238-03 10 Structure,function and maintenance standard
Maintenance function
q Pressing F5 on the normal screen switches to
the maintenance screen.
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)
F5: Returns to the normal screen.
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.
54 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 55
SEN02238-03 10 Structure,function and maintenance standard
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.
56 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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 are300 l/min.
PC400, 450-8 57
SEN02238-03 10 Structure,function and maintenance standard
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: Selects (highlights) an item one down. Flow level Flow (l/min) Remarks
F4: Selects (highlights) an item one up. 8 550 Default
F5: Returns to the attachment setting menu. 7 476
F6: Specifies the selected (highlighted) item as a 6 401
flow rate in attachment mode. 5 327
q Selecting “No attachment" disables selection 4 253
of attachment mode on the working mode se- 3 179
lection screen. 2 104
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.
58 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
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.
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.
PC400, 450-8 59
SEN02238-03 10 Structure,function and maintenance standard
1) Time setting
F3: Selects (highlights) an item one down. Adjust the clock time. If the time setting item
F4: Selects (highlights) an item one up. is 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.
60 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Language setting
q Selecting the Language from the user menu
screen and pressing F6 switches to the lan-
guage selection 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.
PC400, 450-8 61
SEN02238-03 10 Structure,function and maintenance standard
62 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 63
SEN02238-03 10 Structure,function and maintenance standard
64 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
Sensors
q The signals from the sensors are input to the
monitor panel directly.
q Either side of a sensor of contact type is always
connected to the chassis ground.
Type of When When
Sensor name
sensor normal abnormal
ON OFF
Hydraulic oil level Contact
(Closed) (Open)
Resis-
Hydraulic oil temperature — —
tance
Resis-
Coolant temperature — —
tance
Resis-
Fuel level — —
tance
OFF ON
Air cleaner clogging Contact
(Closed) (Open)
1. Connector
2. Bracket
3. Float
4. Switch
PC400, 450-8 65
SEN02238-03 10 Structure,function and maintenance standard
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Float 3. Cover
2. Connector 4. Variable resistor
66 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
PC400, 450-8 67
SEN02238-03 10 Structure,function and maintenance standard
68 PC400, 450-8
10 Structure,function and maintenance standard SEN02238-03
KOMTRAX terminal
TH300
PC400, 450-8 69
SEN02238-03 10 Structure,function and maintenance standard
©2011 KOMATSU
All Rights Reserved
Printed in Japan 02-11
70
SEN02643-03
PC400LC-8
SEN02643-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400LC-8 1
SEN02643-03 20 Standard value table
Engine SAA6D125E-5
2 PC400, 450-8
20 Standard value table SEN02643-03
valve
Bucket control
mm
valve 9.5 ± 9.5 ± 9.5 ± 9.5 ±
― ―
Swing control- 0.5 0.5 0.5 0.5
valve
Travel control
BLP00101
valve
Boom control
85 ± 10 85 ± 10
lever
Arm control
Travel of control levers
85 ± 10 85 ± 10
lever
Bucket control q Engine stopped 85 ± 10 85 ± 10
lever q At center of control lever grip
mm
Swing control q Max. reading up to stroke end (except
lever play in NEUTRAL position) 85 ± 10 85 ± 10
lever
Travel control
115 ± 12 115 ± 12
lever
Play of control
Max. 10 Max. 15
lever
Boom control 15.7 ± 4.9 Max. 24.5
Operating effort of control levers
PC400, 450-8 3
SEN02643-03 20 Standard value table
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
q Hydraulic oil temperature:
Within operation range
Unload pres- q Engine at high idle 4.2 ± 1.0 4.2 ± 1.0
sure 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- pres- 18.14 ± 0.98 16.67 – 19.61
LOWER sure setting {185 ± 10} {170 – 200}
q Hydraulic oil tempera-
ture: Within operation At
31.38 ± 1.47 29.2 – 33.34
range high-pres-
{320 ± 15} {300 – 340}
q Engine at high idle sure setting
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
Arm
measurement circuits relieved {355(+15/-10)(380( {340 – 375(365 –
q Values inside parenthesis: Hydraulic oil +15/-10))} 400)}
pressure with power max. switch in ON 34.81 (+1.47/-0.98) 33.34 – 36.77
Hydraulic pressure
4 PC400, 450-8
20 Standard value table SEN02643-03
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Time taken to
sec.
start swing q Hydraulic oil temperature:
Within operation range
q Bucket: Empty
q Engine at high idle 180° 5.4 ± 0.5 Max. 6.4
q Working mode: P-mode
q Time required for passing points
90° and 180° from starting point
Swing
Time taken to
sec. 33.0 ± 3.3 Max. 38
swing q Hydraulic oil temperature:
Within operating range
q Bucket: Empty
q Engine at high idle
q Working mode: P-mode
q Time required for 5 more turns after
making initial one turn
PC400, 450-8 5
SEN02643-03 20 Standard value table
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
q Hydraulic oil temperature: Within opera-
tion range
Swing
Travel speed
q Hydraulic oil temperature: Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel)
Within operating range
q Engine at high idle
q Working mode: P-mode
Travel
6 PC400, 450-8
20 Standard value table SEN02643-03
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Hydraulic drift
mm 0 0
of travel
q Hydraulic oil temperature:
Within operating range
Travel
q Engine stopped
q Parking machine on slope 12° with
sprocket facing upslope
q Sliding distance for 5 minutes
q Hydraulic oil temperature:
Within operating range
Leakage of q Engine at high idle
l/min Max. 20 Max. 40
travel motor q Travel: Lock sprocket.
q Oil leakage amount for one minute with
traveling in relief condition
Whole work
equipment PC400: Max. 600 PC400: Max. 900
(tooth tip fall PC450: Max. 700 PC450: Max. 1050
amount)
Hydraulic drift of work equipment
Boom cylin-
der
PC400: Max. 25 PC400: Max. 38
(cylinder
Work equipment
PC400, 450-8 7
SEN02643-03 20 Standard value table
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
RAISE
PC400: 4.0 ± 0.4 PC400: Max. 4.8
PC450: 4.2 ± 0.4 PC450: Max. 5.0
LOWER
q Engine at high idle PC400: 2.9 ± 0.3 PC400: Max. 3.4
q Working mode: P-mode PC450: 2.8 ± 0.3 PC450: Max. 3.3
q Time required from raise stroke
end till bucket touches ground
Work equipment speed
CURL
PC400: 4.3 ± 0.4 PC400: Max. 5.0
Work equipment
Arm sec.
q Hydraulic oil temperature:
Within operation range
DUMP
Bucket
q Hydraulic oil temperature: Within
operation range
DUMP
8 PC400, 450-8
20 Standard value table SEN02643-03
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Boom q Hydraulic oil temperature: Within opera- sec. Max. 3.0 Max. 3.6
tion range
q Engine at low idle
q Working mode: P-mode
q Time required from raise stroke end till
bucket touches ground and pushes up
machine front
Time lag
q
Internal leakage
PC400, 450-8 9
SEN02643-03 20 Standard value table
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Hydraulic
See next page l/min See next page
pump delivery
10 PC400, 450-8
20 Standard value table SEN02643-03
PC400, 400LC-8
Applicable model
PC450, 450LC-8
Cate- Measurement
Item Unit Standard value Permissible value
gory Condition
Discharge amount of hydraulic pump (P mode)
Performance of hydraulic pump
PC400, 450-8 11
SEN02643-03 20 Standard value table
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
q Engine coolant temperature:
Within operating range
q Hydraulic oil temperature:
2 pumps at relief 1,930 ± 100 1,930 ± 100
Within operating range
q Engine at high idle
Engine speed
Bucket control
mm
valve 9.5 ± 9.5 ± 9.5 ± 9.5 ±
— —
Swing control- 0.5 0.5 0.5 0.5
valve
Travel control
valve BLP00101
Max. 95
Arm control lever 85 ± 10
q Engine stopped Min. 75
Bucket control q At center of control lever grip Max. 95
85 ± 10
lever q Max. reading up to stroke end Min. 75
mm
Swing control (excepting lever play in NEUTRAL position) Max. 95
85 ± 10
lever Min. 75
Travel control Max. 127
115 ± 12
lever Min. 103
Play of control Work equip-
Max. 10 Max. 15
lever ment, swing
Boom control 15.68 ± 3.92 Max. 24.5
Operating effort of control levers
12 PC400, 450-8
20 Standard value table SEN02643-03
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
q Hydraulic oil temperature:
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 con-
trol levers in NEUTRAL position
33.83 – 36.28 33.34 – 36.77
Raise
{345 – 380} {340 – 375}
At low-
pres- 30.9 – 33.8 30.38 – 34.3
sure {315 – 345} {310 – 350}
LOWER
Boom
setting
At
high-pr 17.1 – 20.5 16.66 – 21.07
essure {175 – 210} {170 – 215}
setting
31.8 – 34.3 31.36 – 34.79
IN
{325 – 350} {320 – 355}
Arm
31.8 – 34.3 31.36 – 34.79
OUT
{325 – 350} {320 – 355}
q Oil temperature: 45 – 55°C 32.3 – 34.79 {31.85 – 35.28
q Engine at full throttle CURL
{325 – 355} {325 – 355}
Bucket q In heavy duty mode
q Pump outlet port pressure 31.8 – 34.3 31.36 – 34.79
DUMP
Hydraulic pressure
PC400, 450-8 13
SEN02643-03 20 Standard value table
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
Work equipment posture: Max. reach
Overrun when
deg. 120 150
stopping swing
Time taken to
sec.
start swing
Time taken to
sec. 33.7 ± 1.7 Max. 38
swing
Hydraulic drift of
q Engine stopped mm 0 0
swing
q Hydraulic oil temperature: 45 – 55°C
q Set machine on 15° slope, and set upper
structure at 90° to the side
q Make match marks on swing circle outer race
and track frame
q Measure distance that match marks move
apart after 5 minutes
14 PC400, 450-8
20 Standard value table SEN02643-03
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
q Engine at full throttle
Swing
Travel speed
Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel)
q Hydraulic oil temperature: Within op-
eration range
Travel
PC400, 450-8 15
SEN02643-03 20 Standard value table
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
Hydraulic drift of
mm 0 0
travel
q Engine stopped
q Hydraulic oil temperature:
45 – 55°C
q Stop machine on 12° slope with sprocket fac-
ing straight up the slope
Travel
Leakage of travel
l/min Max. 20 Max. 40
motor
Boom cylinder
(cylinder
Max. 25 Max. 38
retraction
Work equipment
16 PC400, 450-8
20 Standard value table SEN02643-03
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
RAISE
Boom
4.7 ± 0.5 Max. 5.7
Bucket teeth in
contact with
ground
I
O
LOWER
Cylinder fully q Engine at full throttle 3.7 ± 0.4 Max. 4.5
extended q Hydraulic oil temperature:
45 – 55°C
q In A mode
CURL
Arm 2.6 ± 0.3 Max. 3.2
Cylinder fully
retracted
I
O DUMP
Work equipment speed
Cylinder fully
retracted
I
O q Engine at full throttle
DUMP
Cylinder fully
retracted q Engine at full throttle
I q Hydraulic oil temperature:
O
CLOSE
45 – 55°C
Fully extended q In A mode 2.1 ± 0.3 Max. 2.7
PC400, 450-8 17
SEN02643-03 20 Standard value table
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
sec.
18 PC400, 450-8
20 Standard value table SEN02643-03
Cate- Permissible
Item Measurement conditions Unit Standard value
gory value
Work equipment
Internal leakage
Hydraulic
See next page l/min See next page
pump delivery
PC400, 450-8 19
SEN02643-03 20 Standard value table
Cate- Measurement
Item Unit Standard value Permissible value
gory condition
20 PC400, 450-8
20 Standard value table SEN02643-03
PC400, 450-8 21
SEN02643-03 20 Standard value table
©2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
22
SEN02644-04
PC400LC-8
SEN02644-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400, 450-8 1
SEN02644-04 30 Testing and adjusting
2 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 3
SEN02644-04 30 Testing and adjusting
Sym-
Testing and adjusting item Part number Part name Q'ty Remarks
bol
799-101-5002 Hydraulic tester 1
1 * Common with G1
790-261-1204 Digital hydraulic tester 1
Testing and adjusting oil
pressure in pump LS con- O 2 799-101-5220 Nipple 4
* Common with M2
trol circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
799-101-5002 Hydraulic tester 1
1 * Common with G1
790-261-1204 Digital hydraulic tester 1
Testing solenoid valve out- 799-401-3100 Adapter 1 Size : 02
P 2
put pressure 02896-11008 O-ring 1
799-401-3200 Adapter 1 Size : 03
3
02896-11009 O-ring 1
799-101-5002 Hydraulic tester 1
Testing PPC valve output 1 * Common with G1
Q 790-261-1204 Digital hydraulic tester 1
pressure
2 790-301-1730 Joint 1 Size : PF1/4 + PT1/4
Commercially
Testing 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
799-601-4180 q T-adapter 1 For EGR gas sensor
— 799-601-4211 q T-adapter 1 For controller (50-pole)
799-601-4220 q T-adapter 1 For controller (60-pole)
799-601-4240 q Socket 1 For ambient pressure sensor
799-601-4250 q Socket 1 For Bkup sensor
799-601-4260 q T-adapter 1 For controller (4-pole)
799-601-4330 q Socket 1 For Bkup sensor
799-601-4350 q T-box 1 For 60-pole type
Troubleshooting for/engine For coolant temperature sensor
controller/sensors/actua- 795-799-5530 q T-adapter 1
For fuel temperature sensor
tors 795-799-5540 q T-adapter 1 For boost temperature sensor
For EGR valve solenoid
799-601-9020 q T-adapter 1 For bypass valve solenoid
For injector
For EGR valve solenoid
799-601-9030 q T-adapter 1
For bypass valve stroke sensor
— 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
799-601-9100 T-adapter assembly 1
or
799-601-9300
799-601-9310 q Plate 1
For 24-pole type
799-601-9320 q T-box 1
4 PC400, 450-8
30 Testing and adjusting SEN02644-04
Sym-
Testing and adjusting item Part number Part name Q'ty Remarks
bol
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
Troubleshooting for chas-
799-601-4200
sis/sensors/wiring har- —
or T-adapter assembly 1
nesses
799-601-9000
or
799-601-9200
799-601-9020 q Adapter for DT 1
799-601-9030 q Adapter for DT 1
799-601-9420 q Adapter for AMP 1 For A3P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7010 q Adapter for X 1
799-601-7020 q Adapter for X 1 For X2P
799-601-7040 q Adapter for X 1 For X4P
PC400, 450-8 5
SEN02644-04 30 Testing and adjusting
Sym-
Testing and adjusting item Part number Part name Q'ty Remarks
bol
For SW6P
799-601-7050 q Adapter for SWP 1
(Does not include 799-601-8000)
For SW8P
799-601-7060 q Adapter for SWP 1
(Does not include 799-601-8000)
For SW14P
799-601-7070 q Adapter for SWP
(Does not include 799-601-8000)
For M1P
799-601-7080 q Adapter for M 1 (Does not include 799-601-7000 and
799-601-7100)
799-601-7090 q Adapter for M 1 For M2P
799-601-7110 q Adapter for M 1 For M3P
799-601-7120 q Adapter for M 1 For M4P
799-601-7130 q Adapter for M 1 For M6P
799-601-7140 q Adapter for M 1 For S8P
799-601-7160 q Adapter for M 1 For S12P
Troubleshooting for chas- 799-601-7170 q Adapter for M 1 For S16P
sis/sensors/wiring har- — 799-601-7210 q Adapter for AMP040 1 For A16P
nesses
799-601-7220 q Adapter for AMP040 1 For A20P
799-601-7320 q Adapter for SWP 1 For SW16P
799-601-7340 q Adapter for M 1 For M8P
799-601-7360 q Adapter for relay 1 For REL-5P
799-601-7370 q Adapter for relay 1 For REL-6P
799-601-7500 T-adapter assembly 1
799-601-7520 q Adapter for 070 1 For 070-12P
799-601-9000
or T-adapter assembly 1
799-601-9200
799-601-9030 q Adapter for DT 1
799-601-9110 q Adapter for DT (GR) 1 For DT12PGR
799-601-9350 q Adapter for DRC 1 For DRC-40
799-601-9360 q Adapter for DRC 1 For DRC-24
Testing wear on sprocket — 796-627-1120 Wear gauge 1
Testing coolant tempera-
— 799-101-1502 Digital thermometer 1 -99.9 - 1,299°C
ture and oil temperature
Testing 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}
Testing stroke and hydrau- Commercially
— Ruler 1
lic drift available
Testing work equipment Commercially
— Stopwatch 1
speed available
Testing voltage and resis- Commercially
— Circuit tester 1
tance available
1 21 mm deep socket
Commercially (MITOLOY 4ML-21 or equivalent)
Socket
available Applied engine serial number:
Removal and installation
560001-564999
of engine coolant tempera- —
1 19 mm deep socket
ture sensor
(MITOLOY 4ML-19 or equivalent)
795T-981-1010 Socket
Applied engine serial number:
560001-
6 PC400, 450-8
30 Testing and adjusting SEN02644-04
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
PC400, 450-8 7
SEN02644-04 30 Testing and adjusting
8 PC400, 450-8
30 Testing and adjusting SEN02644-04
Testing air boost pressure 3. Run the engine at middle or higher speed and
bleed oil from the hose.
a Air boost pressure measuring tools
a When draining the oil, open the self seal of
Symbol Part number Part name
the hose by inserting approximately half of
799-201-2202 Boost gauge kit
A the gauge and hose connection. Repeat op-
799-401-2220 Hose
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.
PC400, 450-8 9
SEN02644-04 30 Testing and adjusting
2. Install sensor [1] of digital thermometer B and 6. Remove the measurement tool after the
connect it to meter [2]. measurement, and make sure that the machine
a Clamp the digital thermometer harness so is back to normal condition.
that it may not be accidentally contacted 3 Exhaust temperature measuring plug:
against a hot part. 3.9 - 6.9 Nm {0.4 - 0.7 kgm}
10 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 11
SEN02644-04 30 Testing and adjusting
12 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 13
SEN02644-04 30 Testing and adjusting
Testing 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).
Symbol Part number Part name
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)
14 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 15
SEN02644-04 30 Testing and adjusting
16 PC400, 450-8
30 Testing and adjusting SEN02644-04
Testing engine oil pressure 4. Run the engine until the engine coolant is heated
up to the operating range.
a Engine oil pressure measurement tools
Symbol Part number Part name
799-101-5002 Hydraulic tester
5. Measure the engine oil pressure at low idle and
1 also at high idle.
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge
PC400, 450-8 17
SEN02644-04 30 Testing and adjusting
18 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 19
SEN02644-04 30 Testing and adjusting
Testing 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 number Part name
is normal.
799-101-5002 Hydraulic tester
1 Engine speed Fuel pressure
H 790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge 0.15 – 0.3 MPa
High idle
{1.5 – 3 kg/cm2}
20 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 21
SEN02644-04 30 Testing and adjusting
22 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 23
SEN02644-04 30 Testing and adjusting
24 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 25
SEN02644-04 30 Testing and adjusting
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}
26 PC400, 450-8
30 Testing and adjusting SEN02644-04
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-
following procedure.
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 check it
a If any fuel leakage is detected, repair it and
easily 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.
PC400, 450-8 27
SEN02644-04 30 Testing and adjusting
Checking and adjusting fan belt 4. Slide alternator (6) by rotating adjusting nut (7),
and alternator belt adjust V belt (8) tension and tighten locknut (5).
a Nut (6):
q Tightening the locknut clockwise moves it
Checking to the belt-loosening side.
1. Open the engine hood and remove the belt q Tightening the locknut counterclockwise
protection covers (2 covers). moves it to the belt-tightening side.
a Check the pulleys for breakage, V-groove for
2. Press the intermediate point of the belt between wear, V-belt for wear and contact of the
fan pulley and compressor pulley with a finger V-belt and V-groove for any trouble.
and measure deflection (a) of the belt. a A belt must be replaced with a new one when
a Deflection (a) when pressing force of approx. it is elongated so as to eliminate the adjust-
58.8 N {approx. 6 kg} is applied: ment allowance, or when cuts or cracks are
13 - 16 mm visible on it.
Adjusting
a If the V belt deflection is abnormal, adjust it ac-
cording to the following procedure.
28 PC400, 450-8
30 Testing and adjusting SEN02644-04
Checking and adjusting air condi- 3. Slide compressor (6) by loosening locknut (4)
tioner compressor belt tension and rotating adjusting nut (5), adjust V-belt (7)
tension and tighten locknut (4).
a Check the pulleys for breakage, V-groove for
Checking wear, V-belt for wear and contact of the
1. Open the engine hood and remove the belt V-belt and V-groove for any trouble.
protection covers (2 covers). a A belt must be replaced with a new one when
it is elongated so as to eliminate the adjust-
2. Press the intermediate point of the belt between ment allowance, or when cuts or cracks are
air compressor pulley and drive pulley with a visible on it.
finger and measure deflection (a) of the belt. 4. Tighten mounting bolt (2) and fixing bolt (3).
a Pressing force: Deflection (a) when pressing a When a V-belt is replaced, adjust the tension
force of approx. 58.8 N {approx. 6 kg} is ap- again after operating the machine for an
plied: 14 - 16 mm hour.
Adjusting
a If the belt deflection is abnormal, adjust it accord-
ing to the following procedure.
1. Open the inspection cover of the engine hood
and remove cover (1).
PC400, 450-8 29
SEN02644-04 30 Testing and adjusting
Testing swing circle bearing clear- 3. Set dial gauge to the zero point.
ance
a Swing circle bearing clearance measurement
tools
Symbol Part No. Part name
Commercially
K Dial gauge
available
30 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 31
SEN02644-04 30 Testing and adjusting
Testing and adjustment 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 60
and travel circuits
MPa {600 kg/cm2}.
a Measuring and adjusting tools for hydraulic oil
pressure in hydraulic circuit for work equipment,
swing and travel
Symbol Part number Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
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).
32 PC400, 450-8
30 Testing and adjusting SEN02644-04
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
F main relief valve played.
Arm Hi
Front
Bucket F main relief valve a The relief pressure of the swing motor is
Left travel
F main relief valve lower than the main relief pressure.
Raise: F main relief valve
Boom
Lower: Safety-suction valve 6. Measurement of travel circuit relief pressure
(Pump merge-divider valve) (Travel junction valve)
1) Start the engine, and lock the travel.
k Put pin [2] between the sprocket and
(Self pressure reducing valve)
Swing Swing motor safety valve
Rear Right travel R main relief valve track frame to lock the travel mecha-
Arm Lo R main relief valve nism securely.
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)
PC400, 450-8 33
SEN02644-04 30 Testing and adjusting
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 high-pressure relief pressure mode de-
too.). notes the state in which the machine push-up
a When the low-pressure relief pressure is switch is turned on, disabling to apply the pi-
turned on, the 2-stage relief valve is OFF and lot pressure to the switching port.
thus the pilot pressure is not applicable to the
switching port.
34 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 35
SEN02644-04 30 Testing and adjusting
Testing control circuit basic pres- 3. Start the engine and keep it running until the
sure 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 number Part name is running at high idle and all the control levers
799-101-5002 Hydraulic tester
1 are moved to the NEUTRAL position.
790-261-1204 Digital hydraulic tester
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
k Lower the work equipment to the ground
and, after stopping the engine, release 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.
36 PC400, 450-8
30 Testing and adjusting SEN02644-04
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
and adjusting tools
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.
k Lower the work equipment to the ground
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- q The figure shows the PC valve output
side the tank. side.
PC400, 450-8 37
SEN02644-04 30 Testing and adjusting
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 teste 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 Working mode: P-mode
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
Oil pressure ratio
pressure
Pump discharge
1
pressure 3) Start the engine and keep it running until the
PC valve output hydraulic oil temperature rises to the oper-
Approx. 0.6 (Approx. 3/5)
pressure ating range.
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.
5) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
38 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 39
SEN02644-04 30 Testing and adjusting
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
q The figure shows the pump discharge
Symbol Part number Part name
pressure side.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
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.
k Lower the work equipment to the ground
and, after stopping the engine, release resid-
ual pressure in the piping by operating the
control lever several times. Then loosen the q The figure shows the LS valve output
oil filler cap gradually to release pressure in- side.
side the tank.
40 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 41
SEN02644-04 30 Testing and adjusting
42 PC400, 450-8
30 Testing and adjusting SEN02644-04
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 speed Travel lever Oil pressure
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).
PC400, 450-8 43
SEN02644-04 30 Testing and adjusting
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
44 PC400, 450-8
30 Testing and adjusting SEN02644-04
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 number Part name a Use the oil pressure gauge with capacity 6.0
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester MPa {60 kg/cm2}.
799-401-3100 Adapter (Size 02) a Figure shows the outlet hose of the 2-stage
P 2
02896-11008 O-ring solenoid valve being installed with the mea-
799-401-3200 Adapter (Size 03) suring tool.
3
02896-11009 O-ring
PC400, 450-8 45
SEN02644-04 30 Testing and adjusting
a When each output pressure shows the fol- 6. Remove the measurement tool after the
lowing values, it is judged normal. measurement, and make sure that the machine
Solenoid valve Output pressure is back to normal condition.
OFF (De-energized) 0 MPa {0 kg/cm2}
Almost the same pressure as the
ON (Energized) control circuit basic pressure
(See "Standard values tableÅh)
46 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 47
SEN02644-04 30 Testing and adjusting
48 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 49
SEN02644-04 30 Testing and adjusting
50 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 51
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52 PC400, 450-8
30 Testing and adjusting SEN02644-04
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 posture 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".
PC400, 450-8 53
SEN02644-04 30 Testing and adjusting
54 PC400, 450-8
30 Testing and adjusting SEN02644-04
a Use the following part to block the hose. a Continue this condition for 30 seconds,
07379-01044 (Flange#10) then measure the oil leakage amount for
one minute.
a After measuring 1 time, swing 180° and
then measure again.
5) After the measurement, make sure that the
machine is back to normal condition.
PC400, 450-8 55
SEN02644-04 30 Testing and adjusting
56 PC400, 450-8
30 Testing and adjusting SEN02644-04
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
PC400, 450-8 57
SEN02644-04 30 Testing and adjusting
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: 9.8 - 12.74 Nm {1.0 - 1.3
mounted.
1) Start the engine and keep running at low idle 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 rod about 100 mm in front
of the stroke end so that it may not be re-
lieved.
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.
58 PC400, 450-8
30 Testing and adjusting SEN02644-04
PC400, 450-8 59
SEN02644-04 30 Testing and adjusting
©2011 KOMATSU
All Rights Reserved
Printed in Japan 07-11
60
SEN02645-06
PC400LC-8
SEN02645-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400, 450-8 1
SEN02645-06 30 Testing and adjusting
2 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 3
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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 32p
System
A Display of warning after check before starting 8p Maintenance Record 33p
A Display of ending of maintenance interval 8p Maintenance Mode Change 34p
Display of check of working mode and travel
A 8p Phone Number Entry 36p
speed
A Display of ordinary screen 8p Key-on Mode 37p
A Display of end screen 9p Unit 38p
B Selection of auto-deceleration 9p With/Without Attachment 39p
Attachment/Maintenance Pass-
B Selection of working mode 9p Default 40p
O (Special operation)
word
B Selection of travel speed 10p Camera 41p
B Operation to stop alarm buzzer 10p ECO Display 42p
B Operation of windshield wiper 11p Breaker Detect 43p
B Operation of window washer 11p Pump Absorption Torque 44p
B Operation of air conditioner/heater 11p Low Speed 45p
Adjustment
Operation to display camera mode (if camera is
B 12p Attachment Flow Adjustment 46p
installed)
B Operation to display clock and service meter 12p Cylinder Cut-Out 47p
B Check of maintenance information 13p No Injection 48p
Setting and display of user mode
B 13p Fuel Consumption 50p
(Including KOMTRAX messages for user)
C Display of energy-saving guidance 14p Terminal Status 51p
C Display of caution monitor 14p KOMTRAX GPS & Communication Status 52p
C Display of automatic judgment of breaker 15p Settings
MODEM S/N (TH300) 53p
C Display of user code and failure code 15p
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, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 5
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6 PC400, 450-8
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PC400, 450-8 7
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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".
8 PC400, 450-8
30 Testing and adjusting SEN02645-06
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, 450-8 9
SEN02645-06 30 Testing and adjusting
10 PC400, 450-8
30 Testing and adjusting SEN02645-06
a Heater specification
PC400, 450-8 11
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Operation to display camera mode (if camera is a When two or more cameras are connected, the
installed) image of one of them or the images of two of
When a camera is installed, if [F3] is pressed, the them can be displayed.
multi-display changes to the camera image (Set the If 2-camera image display [F4] is selected, the
connection of the camera in the service mode). 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.
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, 450-8
30 Testing and adjusting SEN02645-06
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 Adjustmen
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, 450-8 13
SEN02645-06 30 Testing and adjusting
14 PC400, 450-8
30 Testing and adjusting SEN02645-06
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.
PC400, 450-8 15
SEN02645-06 30 Testing and adjusting
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
EOE Network error
immediately.
16 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 17
SEN02645-06 30 Testing and adjusting
18 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 19
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20 PC400, 450-8
30 Testing and adjusting SEN02645-06
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..
PC400, 450-8 21
SEN02645-06 30 Testing and adjusting
22 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 23
SEN02645-06 30 Testing and adjusting
24 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 25
SEN02645-06 30 Testing and adjusting
1. Selecting menu
Select “Abnormality Record” on the “Service
Menu” Screen. 3. Information displayed on "abnormality record"
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-
displayed, select "Electrical Systems" with the q [F4]: Move to upper item
function switches or numeral input switches. q [F5]: Return to “abnormality record” screen
26 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 27
SEN02645-06 30 Testing and adjusting
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. (If the [F2] switch is depressed to
delete all the information, “Reset All?” is
displayed.).
28 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 29
SEN02645-06 30 Testing and adjusting
Device in
Action code Failure code Trouble (Displayed on screen) Category of record
charge
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
E14 CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E15 CA689 Ne Speed Sensor Error ENG Electrical system
E15 CA731 Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E15 CA778 Bkup Speed Sensor Error ENG Electrical system
E15 CA1228 EGR Valve Servo Error 1 ENG Electrical system
E11 CA1625 EGR Valve Servo Error 2 ENG Electrical system
— CA1633 KOMNET Datalink Timeout Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
— D110KB Battery Relay Drive Short Circuit PUMP Electrical system
E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical system
— D862KA GPS Antenna Discon MON2 Electrical system
— DA22KK Pump Solenoid Power Low Error PUMP Electrical system
E02 DA25KP 5V sensor power supply output 1 abnormality PUMP Electrical system
— DA29KQ Model Selection Abnormality PUMP Electrical system
E0E DA2RMC CAN discon (Pump con detected) PUMP Electrical system
— DAF8KB Short circuit in camera power supply PUMP Electrical system
— DAFGMC GPS Module Error PUMP Electrical system
E0E DAFRMC CAN discon (Monitor detected) PUMP Electrical system
— DGH2KB Hyd Oil Sensor Short PUMP Electrical system
— DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system
— DHX1MA Overload Sensor Abnormality (Analog) PUMP Electrical system
— DW43KA Travel Speed Sol. Open Circuit PUMP Electrical system
— DW43KB Travel Speed Sol. Short Circuit PUMP Electrical system
E03 DW45KA Swing Brake Sol. Open Circuit PUMP Electrical system
E03 DW45KB Swing Brake Sol. Short Circui PUMP Electrical system
— DW91KA Travel Junction Sol. Open Circuit PUMP Electrical system
— DW91KB Travel Junction Sol. Short Circuit PUMP Electrical system
— DWA2KA Attachment Sol Open Circuit PUMP Electrical system
30 PC400, 450-8
30 Testing and adjusting SEN02645-06
Device in
Action code Failure code Trouble (Displayed on screen) Category of record
charge
— DWA2KB Attachment Sol Short Circuit PUMP Electrical system
— DWJ0KA Merge-divider Sol. Open Circuit PUMP Electrical system
— DWJ0KB Merge-divider Sol. Short Circuit PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Open Circuit PUMP Electrical system
— DWK0KB 2-stage Relief Sol. Short Circuit PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Open Circuit PUMP Electrical system
E02 DXA0KB PC-EPC Sol. Short Circuit PUMP Electrical system
— DXE0KA LS-EPC Sol. Open Circuit PUMP Electrical system
— DXE0KB LS-EPC Sol. Short Circuit PUMP Electrical system
— DXE4KA Service Current EPC Open Circuit PUMP Electrical system
— DXE4KB Service Current EPC Short Circuit PUMP Electrical system
— DY20KA Wiper Working Abnormality PUMP Electrical system
— DY20MA Wiper Parking Abnormality PUMP Electrical system
— DY2CKA Washer Drive Open Circuit PUMP Electrical system
— DY2CKB Washer Drive Short Circuit PUMP Electrical system
— DY2DKB Wiper Drive (Fwd) Short Circuit PUMP Electrical system
— DY2EKB Wiper Drive (Rev) Short Circuit PUMP Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
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 Alarm buzzer
q: When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop the
buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
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.
PC400, 450-8 31
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34 PC400, 450-8
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PC400, 450-8 35
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1. Selecting menu
Select "Phone Number Entry" on the "Service
Menu" screen.
36 PC400, 450-8
30 Testing and adjusting SEN02645-06
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
PC400, 450-8 37
SEN02645-06 30 Testing and adjusting
1. Selecting menu
Select "Default" on the "Service Menu" screen.
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
38 PC400, 450-8
30 Testing and adjusting SEN02645-06
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 [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Default
screen
q [F6]: Confirm selection and return to Default
screen
PC400, 450-8 39
SEN02645-06 30 Testing and adjusting
40 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 41
SEN02645-06 30 Testing and adjusting
1. Selecting menu
Select "Default" on the "Service Menu" screen.
42 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 43
SEN02645-06 30 Testing and adjusting
44 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 45
SEN02645-06 30 Testing and adjusting
46 PC400, 450-8
30 Testing and adjusting SEN02645-06
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.
PC400, 450-8 47
SEN02645-06 30 Testing and adjusting
[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.
48 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 49
SEN02645-06 30 Testing and adjusting
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.
50 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 51
SEN02645-06 30 Testing and adjusting
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 Set- Status", the following items are displayed.
tings”. 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
52 PC400, 450-8
30 Testing and adjusting SEN02645-06
1. Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.
PC400, 450-8 53
SEN02645-06 30 Testing and adjusting
54 PC400, 450-8
30 Testing and adjusting SEN02645-06
PC400, 450-8 55
SEN02645-06 30 Testing and adjusting
© 2012 KOMATSU
All Rights Reserved
Printed in Japan 10-12
56
SEN02662-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02662-02 30 Testing and adjusting
2 PC400, 450-8
30 Testing and adjusting SEN02662-02
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.
PC400, 450-8 3
SEN02662-02 30 Testing and adjusting
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, 450-8
30 Testing and adjusting SEN02662-02
PC400, 450-8 5
SEN02662-02 30 Testing and adjusting
6 PC400, 450-8
30 Testing and adjusting SEN02662-02
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.
PC400, 450-8 7
SEN02662-02 30 Testing and adjusting
8 PC400, 450-8
30 Testing and adjusting SEN02662-02
Pm Clinic service 1
Model name Serial No. Service meter
T PC400-8
h
T PC450-8 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
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, 450-8 9
SEN02662-02 30 Testing and adjusting
10 PC400, 450-8
30 Testing and adjusting SEN02662-02
PC400, 450-8 11
SEN02662-02 30 Testing and adjusting
1. Engine
Checking condition
Standard Mea-
Good
Service limit
Bad
No. Check item Fuel Work- Auto- Operation of Unit value for new sured
Left knob value
control ing decel- work machine value
switch
dial mode eration equipment
1 Engine speed rpm 1,880 – 1,980 1,880 – 1,980
All levers in
Engine oil MAX MPa 0.29 – 0.69 0.18
2 neutral
pressure {kg/cm2} {3.0 – 7.0} {1.8}
OFF
3 Engine speed rpm 975 – 1,025 975 – 1,025
All levers in
Engine oil MIN OFF MPa Min. 0.08 0.05
4 neutral
pressure P {kg/cm2} {Min. 0.8} {0.5}
5 Engine speed rpm 1,730 – 1,930 1,730 – 1,930
Blow-by ON Arm IN relief kPa Max. 1.76 2.94
6
pressure MAX {mmH2O} {Max. 180} {300}
Engine oil All levers in
7 ON OFF rpm 1,200 – 1,400 1,200 – 1,400
pressure neutral
Good
Service limit
Bad
No. Check item Fuel Work- Unit value for sured
control ing Checking posture, etc. value
new machine value
dial mode
No load, work equipment PC400-8 3.6 – 4.4 Max. 4.8
1 Boom RAISE
extended fully PC450-8 3.8 – 4.6 Max. 5.0
PC400-8 3.2 – 4.0 Max. 4.3
2 Arm IN P
PC450-8 3.2 – 4.0 Max. 4.3
PC400-8 3.9 – 4.7 Max. 5.0
3
PC450-8 4.2 – 5.2 Max. 5.4
Boom top horizontal
PC400-8 3.9 – 4.7 Max. 5.0
4 Arm OUT E
PC450-8 4.2 – 5.2 Max. 5.4
PC400-8 4.7 – 5.7 Max. 6.0
5 L
MAX PC450-8 sec 5.1 – 6.1 Max. 6.3
Boom and arm top horizontal PC400-8 3.2 – 4.0 Max. 4.3
6 Bucket CURL
Arm cylinder retracted fully PC450-8 3.2 – 4.0 Max. 4.3
7 Swing (5 turns) Work equipment extended fully 29.7 – 36.3 Max. 3.8
STD 50.6 – 75.8 42.0 – 80.0
LO
P LC 53.8 – 80.8 45.0 – 84.5
STD 38.3 – 51.9 31.5 – 55.0
8 Travel (5 turns) One side of track pushed up MI
LC 40.9 – 55.3 34.0 – 58.0
STD 31.0 – 38.0 28.0 – 41.5
HI
LC 33.1 – 40.3 32.0 – 44.0
12 PC400, 450-8
30 Testing and adjusting SEN02662-02
Good
value for Service limit
Bad
No. Check item Fuel Work- Unit sured
control ing Checking posture, etc. new value
value
dial mode machine
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Good
Bad
No. Checked part cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main LS LS
dial mode
Self pressure A
1 All lever in neutral — — — —
reducing valve
OFF
Main relief valve B B B B
2 —
(Low pressure)
Arm out relief
Main relief valve C C C C
3 ON —
(Low pressure)
D1 D1 D2 D2
4 Unload valve All levers in neutral —
Checked oil pressure Unit Standard value for new machine Service limit value
A (Control circuit basic pressure) 3.04 – 3.44 {31 – 35} 2.84 – 3.43 {29 – 35}
B (Work equipment relief pressure,
33.83 – 36.28 {345 – 370} 33.34 – 36.77 {340 – 375}
Standard value
low)
C (Work equipment relief pressure,
MPa 36.29 – 38.74 {370 – 395} 35.79 – 39.23 {365 – 400}
high)
{kg/cm2}
D (Unload pressure) 3.2 – 5.2 {43 – 53} 3.2 – 5.2 {43 – 53}
E (LS differential pressure) 2.55 – 2.75 {26 – 28} 2.55 – 2.75 {26 – 28}
F (Swing relief pressure) 28.44 – 32.36 {300 – 340} 27.95 – 32.85 {285 – 335}
G (Travel relief pressure) 36.29 – 40.21 {370 – 410} 35.79 – 40.7 {365 – 415}
PC400, 450-8 13
SEN02662-02 30 Testing and adjusting
Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing Control
switch equipment main main servo servo
dial mode
H1 H1 H2 H2
8 Servo piston MAX P OFF Arm out relief —
Standard value
Checked oil pressure Unit Standard value for new machine Service limit value
H1 : H2 = 1 : 0.6
H (Servo control pressure) —
(Oil pressure ratio)
* Gauge changing work: Change [3] and [4] to 60K and change hoses of [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Good
Bad
No. Check item cm2} cm2} cm2} cm2} cm2}
Fuel Work-
Left knob Operation of work F pump R pump F pump R pump
control ing LS-EPC
switch equipment main main (F) (R)
dial mode
J1 J1
MIN — — —
P
J2 J2
— — —
PC-EPC (F)
valve J3 J3
9 E All levers in neutral — — —
PC-EPC (R)
valve J4 J4
L — — —
OFF J5 J5
B — — —
MAX
Travel speed: Lo K1
— — — —
travel lever in neutral
Travel speed: Mi K2
Travel lever oper- — — — —
10 LS-EPC valve P
ated
Travel speed: Hi K3
Travel lever oper- — — — —
ated
Checked oil pressure Unit Standard value for new machine Service limit value
J1 (PC-EPC valve output pressure 1) Approx. 1.5 {Approx. 15}
J2 (PC-EPC valve output pressure 2) Approx. 0.4 {Approx. 4}
Standard value
14 PC400, 450-8
30 Testing and adjusting SEN02662-02
PC400, 450-8 15
SEN02662-02 30 Testing and adjusting
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:
16 PC400, 450-8
30 Testing and adjusting SEN02662-02
PC400, 450-8 17
SEN02662-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
18
SEN02646-03
PC400LC-8
SEN02646-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
40 Troubleshooting
Failure code table and fuse locations
PC400, 450-8 1
SEN02646-03 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02646-03
Reference
Action Failure Device in
Trouble (Displayed on screen) Category of record document
code code charge
No.
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
E15 CA386 Sens Supply 1 Volt High 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
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
E15 CA1228 EGR Valve Servo Error 1 ENG Electrical system by failure code
(Display of code),
E11 CA1625 EGR Valve Servo Error 2 ENG Electrical system Part 2
EOE CA1633 KOMNET Datalink Timeout Error ENG Electrical system SEN02649-02
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error ENG Electrical system
— D110KB Battery Relay Drive Short Circuit PUMP Electrical system
E01 D19JKZ Personal Code Relay Abnormality MON2 Electrical system
— D862KA GPS Antenna Discon MON2 Electrical system
E0E DA22KK Pump Solenoid Power Low Error PUMP Electrical system
E02 DA25KP 5V sensor power supply output 1 abnormality PUMP Electrical system
— DA29KQ Model Selection Abnormality PUMP Electrical system
PC400, 450-8 3
SEN02646-03 40 Troubleshooting
Reference
Action Failure Device in
Trouble (Displayed on screen) Category of record document
code code charge
No.
E0E DA2RMC CAN Discon (Pump Con Detected) PUMP Electrical system
— DAF8KB Short circuit in camera power supply PUMP -
— DAFGMC GPS Module Error PUMP Electrical system
E0E DAFRMC CAN Discon (Monitor Detected) PUMP Electrical system
— DGH2KB Hyd Oil Sensor Short PUMP Electrical system
— DHPAMA F Pump Press Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump Press Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP Electrical system
— DHX1MA Overload Sensor Abnormality (Analog) PUMP Electrical system
— DW43KA Travel Speed Sol. Open Circuit PUMP Electrical system
— DW43KB Travel Speed Sol. Short Circuit PUMP Electrical system
E03 DW45KA Swing Brake Sol. Open Circuit PUMP Electrical system
E03 DW45KB Swing Brake Sol. Short Circuit PUMP Electrical system
— DW91KA Travel Junction Sol. Open Circuit PUMP Electrical system Troubleshooting by
failure code
— DW91KB Travel Junction Sol. Short Circuit PUMP Electrical system
(Display of
— DWA2KA Attachment Sol Open Circuit PUMP Electrical system code),Part 3
— DWA2KB Attachment Sol Short Circuit PUMP Electrical system
SEN02650-03
— DWJ0KA Merge-divider Sol. Open Circuit PUMP Electrical system
— DWJ0KB Merge-divider Sol. Short Circuit PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Open Circuit PUMP Electrical system
— DWK0KB 2-stage Relief Sol. Short Circuit PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Open Circuit PUMP Electrical system
E02 DXA0KB PC-EPC Sol. Short Circuit PUMP Electrical system
— DXE0KA LS-EPC Sol. Open Circuit PUMP Electrical system
— DXE0KB LS-EPC Sol. Short Circuit PUMP Electrical system
— DXE4KA Service Current EPC Open Circuit PUMP Electrical system
— DXE4KB Service Current EPC Short Circuit PUMP Electrical system
— DY20KA Wiper Working Abnormalit PUMP Electrical system
— DY20MA Wiper Parking Abnormality PUMP Electrical system
— DY2CKA Washer Drive Open Circuit PUMP Electrical system
— DY2CKB Washer Drive Short Circuit PUMP Electrical system
— DY2DKB Wiper Drive (Fwd) Short Circuit PUMP Electrical system
— DY2EKB Wiper Drive (Rev) Short Circuit PUMP Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
4 PC400, 450-8
40 Troubleshooting SEN02646-03
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.
PC400, 450-8 5
SEN02646-03 40 Troubleshooting
6 PC400, 450-8
40 Troubleshooting SEN02646-03
PC400, 450-8 7
SEN02646-03 40 Troubleshooting
8 PC400, 450-8
40 Troubleshooting SEN02646-03
PC400, 450-8 9
SEN02646-03 40 Troubleshooting
©2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
10
SEN02647-03
PC400LC-8
SEN02647-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
40 Troubleshooting
General Information on troubleshooting
PC400, 450-8 1
SEN02647-03 40 Troubleshooting
The troubleshooting is to pinpoint the cause of the failure, to perform repairs swiftly, and to prevent reoccur-
rence of the failure. When performing troubleshooting, important point is of course to understand the structure
and function of the machine or component. However, a short cut to effective troubleshooting is to ask the op-
erator various questions to form some idea of probable causes of the failure that would produce the reported
symptoms.
2 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 3
SEN02647-03 40 Troubleshooting
4 PC400, 450-8
40 Troubleshooting SEN02647-03
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, 450-8 5
SEN02647-03 40 Troubleshooting
Possible causes
Possible causes of trouble
and standard
(Given numbers are refer-
value in normal
ence numbers, which do not <Precautions for troubleshooting>
state
indicate priority) (1) Method of indicating connector No. and handling of
Tadapter
Insert or connect T-adapter as explained below for trouble-
shooting, 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 qConnect positive (?) lead to pin No. or wiring harness en-
tered on front side.
qConnect positive (?) lead to pin No. or harness entered on
rear side.
6 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 7
SEN02647-03 40 Troubleshooting
Troubleshooting
No Phenomena supposed to show 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
According
When abnormality record is checked, failure code is dis-
2 to dis-
played in electrical system abnormality record
played
When abnormality record is checked, failure code is dis-
3 code
played in mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2(1)
Engine rotates, but exhaust gas does not
6 Engine does S-2(2)
come out
not start
Engine emits exhaust gas, but it does not
7 S-2(3)
start
Engine does not pick up smoothly (follow-up performance 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
Oil is in coolant, coolant spurts back or coolant level goes
16 S-11
down
17 Oil level rises (Entry of coolant/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 work E-4
Phenomena related to work equipment, swing, and travel
Speed or power of whole work equipment, swing, and travel
23 H-1 S-6
is low
24 Engine speed lowers extremely or engine stalls H-2 S-4
25 Work equipment, swing, and travel systems do not work 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
33 Time lag in generation of work equipment is large H-12
When part of work equipment is relieved singly, other work
34 H-13
equipment move
35 The power maximizing function does not work. E-6, 18-23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part
36 H-16
loaded more is low
When machine swings and boom is raised simultaneously,
37 H-17
boom rising speed goes down
When work equipment and travels simultaneously, travel
38 H-18
speed lowers largely
Phenomena related to travel
39 Machine deviates during travel H-19
40 Travel speed is low E-25 H-20
41 Machine is not steered well or steering power is low E-25, 26 H-21
42 Travel speed does not change or travel speed is low or high E-4 H-22
8 PC400, 450-8
40 Troubleshooting SEN02647-03
Troubleshooting
No Phenomena supposed to show troubles Display of
E-mode H-mode S-mode
code
43 Travel system does not work (only one side) H-23
Phenomena related to swing
44 Upper structure does not swing E-24 H-24
45 Swing acceleration or swing speed is low H-25
46 Upper structure overruns remarkably when it stops swinging H-26
47 Large shock is made when upper structure stops swinging H-27
48 Large sound is made when upper structure stops swinging H-28
49 Hydraulic drift of swing is large H-29
Phenomena related to machine monitor (Operator menu: ordinary screen)
50 Machine monitor does not display any items E-7
51 Machine monitor does not display some items E-8
Contents of display by machine monitor are different from
52 E-9
applicable machine
Radiator coolant level monitor lights up in red during 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
58 AA10NX
running
Engine coolant temperature monitor lights up in red while
59 B@BCNS
engine is running
Hydraulic oil temperature monitor lights up in red while
60 B@HANS
engine is running
Engine coolant temperature gauge does not indicate nor-
61 E-11
mally
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
65 E-15
monitor switch section
66 Windshield wiper does not operate E-16
67 Machine push-up function does not work normally E-17 H-15
Phenomena related to machine monitor (Service menu: special functions screen)
Monitoring function does not display "Boom RAISE" nor-
68 E-18
mally
Monitoring function does not display "Boom LOWER" nor-
69 E-19
mally
70 Monitoring function does not display "Arm IN" normally E-20
71 Monitoring function does not display "Arm OUT" normally E-21
Monitoring function does not display "Bucket CURL" nor-
72 E-22
mally
Monitoring function does not display "Bucket DUMP" nor-
73 E-23
mally
74 Monitoring function does not display "Swing" normally E-24
75 Monitoring function does not display "Travel" normally E-25
Monitoring function does not display "Travel Steering" nor-
76 E-26
mally
77 Monitoring function does not display "Service" normally E-27
Phenomena related to KOMTRAX
78 KOMTRAX system does not work normally E-28
Other phenomena
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
PC400, 450-8 9
SEN02647-03 40 Troubleshooting
10 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 11
SEN02647-03 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 13
SEN02647-03 40 Troubleshooting
14 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 15
SEN02647-03 40 Troubleshooting
16 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 17
SEN02647-03 40 Troubleshooting
18 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 19
SEN02647-03 40 Troubleshooting
20 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 21
SEN02647-03 40 Troubleshooting
22 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 23
SEN02647-03 40 Troubleshooting
24 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 25
SEN02647-03 40 Troubleshooting
26 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 27
SEN02647-03 40 Troubleshooting
28 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 29
SEN02647-03 40 Troubleshooting
30 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 31
SEN02647-03 40 Troubleshooting
32 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 33
SEN02647-03 40 Troubleshooting
34 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 35
SEN02647-03 40 Troubleshooting
36 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 37
SEN02647-03 40 Troubleshooting
38 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 39
SEN02647-03 40 Troubleshooting
40 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 41
SEN02647-03 40 Troubleshooting
42 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 43
SEN02647-03 40 Troubleshooting
44 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 45
SEN02647-03 40 Troubleshooting
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
46 PC400, 450-8
40 Troubleshooting SEN02647-03
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
PC400, 450-8 47
SEN02647-03 40 Troubleshooting
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
48 PC400, 450-8
40 Troubleshooting SEN02647-03
PC400, 450-8 49
SEN02647-03 40 Troubleshooting
©2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
50
SEN02648-04
PC400LC-8
SEN02648-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
40 Troubleshooting
Troubleshooting by failure code, Part 1
PC400, 450-8 1
SEN02648-04 40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 37
Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 39
Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................. 41
Failure code [CA221] Ambient Press Sens High Error ............................................................................... 43
Failure code [CA222] Ambient Press Sens Low Error ................................................................................ 45
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................. 47
Failure code [CA234] Eng Overspeed ........................................................................................................ 48
Failure code [CA238] Ne Speed Sens Supply Volt Error ............................................................................ 49
Failure code [CA263] Fuel Temp Sensor High Error .................................................................................. 50
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................................... 52
Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 53
Failure code [CA272] IMV/PCV1 Open Error.............................................................................................. 55
Failure code [CA273] PCV2 Short Error ..................................................................................................... 57
Failure code [CA274] PCV2 Open Error ..................................................................................................... 59
Failure code [CA322] Inj #1 Open/Short Error ............................................................................................ 61
Failure code [CA323] Inj #5 (L/B#5) Open/Short Error ............................................................................... 63
Failure code [CA324] Inj #3 (L/B#3) Open/Short Error ............................................................................... 65
Failure code [CA325] Inj #6 Open/Short Error ............................................................................................ 67
Failure code [CA331] Inj #2 Open/Short Error ............................................................................................ 69
Failure code [CA332] Inj #4 Open/Short Error ............................................................................................ 71
2 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 3
SEN02648-04 40 Troubleshooting
4 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 5
SEN02648-04 40 Troubleshooting
6 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 7
SEN02648-04 40 Troubleshooting
8 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 9
SEN02648-04 40 Troubleshooting
10 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 11
SEN02648-04 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 13
SEN02648-04 40 Troubleshooting
14 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 15
SEN02648-04 40 Troubleshooting
16 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 17
SEN02648-04 40 Troubleshooting
18 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 19
SEN02648-04 40 Troubleshooting
20 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 21
SEN02648-04 40 Troubleshooting
22 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 23
SEN02648-04 40 Troubleshooting
24 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 25
SEN02648-04 40 Troubleshooting
26 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 27
SEN02648-04 40 Troubleshooting
28 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 29
SEN02648-04 40 Troubleshooting
30 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 31
SEN02648-04 40 Troubleshooting
32 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 33
SEN02648-04 40 Troubleshooting
34 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 35
SEN02648-04 40 Troubleshooting
36 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 37
SEN02648-04 40 Troubleshooting
38 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 39
SEN02648-04 40 Troubleshooting
40 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 41
SEN02648-04 40 Troubleshooting
42 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 43
SEN02648-04 40 Troubleshooting
44 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 45
SEN02648-04 40 Troubleshooting
46 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 47
SEN02648-04 40 Troubleshooting
48 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 49
SEN02648-04 40 Troubleshooting
50 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 51
SEN02648-04 40 Troubleshooting
52 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 53
SEN02648-04 40 Troubleshooting
54 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 55
SEN02648-04 40 Troubleshooting
56 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 57
SEN02648-04 40 Troubleshooting
58 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 59
SEN02648-04 40 Troubleshooting
60 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 61
SEN02648-04 40 Troubleshooting
62 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 63
SEN02648-04 40 Troubleshooting
64 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 65
SEN02648-04 40 Troubleshooting
66 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 67
SEN02648-04 40 Troubleshooting
68 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 69
SEN02648-04 40 Troubleshooting
70 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 71
SEN02648-04 40 Troubleshooting
72 PC400, 450-8
40 Troubleshooting SEN02648-04
PC400, 450-8 73
SEN02648-04 40 Troubleshooting
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
74
SEN02649-03
PC400LC-8
SEN02649-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
40 Troubleshooting
Troubleshooting by failure code, Part 2
PC400, 450-8 1
SEN02649-03 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 3
SEN02649-03 40 T r o u b l es h o o t i n g
4 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 5
SEN02649-03 40 Troubleshooting
Disconnect sensor
and wiring harness at Ambient pressure
right in order and PAMB
sensor
carry out operation to
Defective sensor or wiring
1 reproduce trouble. If
harness
“E” of failure code
Possiblecauses goes off when sensor
and standard or wiring harness is
value in normal disconnected, that Engine wiring har-
CE01
state sensor or wiring har- ness
ness is defective.
6 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 7
SEN02649-03 40 Troubleshooting
8 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 9
SEN02649-03 40 Troubleshooting
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)
a Prepare with starting switch OFF, then turn starting switch ON and
Defective relay for engine carry out troubleshooting.
4
controller power supply Replace relay (R23, R24) for engine controller with another relay and
perform reproducing operation. If “E” of failure code goes off at this
Short circuit in wiring har- Between CE03 (female) (3) – CE03 (female) Resis-
Min.100 k
ness (1) pins (With battery terminal disconnected) tance
7
(with another wiring har- Between CE03 (female) (3) – each of CE02 Resis-
ness) (female) pins (With battery terminal discon- Min.100 k
tance
Between CE03 (female) (1) – each of CE02 Resis-
(female) pins (With battery terminal discon- Min.100 k
tance
Defective wiring harness Connecting parts between fuse No. 19 – machine wiring harness –
8 engine controller may be defective. Check them directly.
connector
10 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 11
SEN02649-03 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 13
SEN02649-03 40 Troubleshooting
14 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 15
SEN02649-03 40 Troubleshooting
Circuit diagram related to common rail pressure sensor and engine controller ground line
16 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 17
SEN02649-03 40 Troubleshooting
18 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 19
SEN02649-03 40 Troubleshooting
20 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 21
SEN02649-03 40 Troubleshooting
22 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 23
SEN02649-03 40 Troubleshooting
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
24 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 25
SEN02649-03 40 Troubleshooting
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When the
engine is installed to the machine, however, the operation load equivalent to the rating depends on the
machine model.
26 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 27
SEN02649-03 40 Troubleshooting
28 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 29
SEN02649-03 40 Troubleshooting
30 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 31
SEN02649-03 40 Troubleshooting
32 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 33
SEN02649-03 40 Troubleshooting
34 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 35
SEN02649-03 40 Troubleshooting
36 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 37
SEN02649-03 40 Troubleshooting
38 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 39
SEN02649-03 40 Troubleshooting
40 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 41
SEN02649-03 40 Troubleshooting
42 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 43
SEN02649-03 40 Troubleshooting
44 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 45
SEN02649-03 40 Troubleshooting
46 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 47
SEN02649-03 40 Troubleshooting
48 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 49
SEN02649-03 40 Troubleshooting
50 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 51
SEN02649-03 40 Troubleshooting
52 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 53
SEN02649-03 40 Troubleshooting
54 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 55
SEN02649-03 40 Troubleshooting
Configuration drawing
56 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 57
SEN02649-03 40 Troubleshooting
58 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 59
SEN02649-03 40 Troubleshooting
60 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 61
SEN02649-03 40 Troubleshooting
62 PC400, 450-8
40 Troubleshooting SEN02649-03
PC400, 450-8 63
SEN02649-03 40 Troubleshooting
©2009 KOMATSU
All Rights Reserved
Printed in Japan 08-09
64
SEN02650-04
PC400LC-8
SEN02650-03
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
40 Troubleshooting
Troubleshooting by failure code, Part 3
PC400, 450-8 1
SEN02650-04 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 3
SEN02650-04 40 Troubleshooting
4 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 5
SEN02650-04 40 Troubleshooting
6 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 7
SEN02650-04 40 Troubleshooting
8 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 9
SEN02650-04 40 Troubleshooting
10 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 11
SEN02650-04 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 13
SEN02650-04 40 Troubleshooting
14 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 15
SEN02650-04 40 Troubleshooting
16 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 17
SEN02650-04 40 Troubleshooting
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
18 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 19
SEN02650-04 40 Troubleshooting
20 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 21
SEN02650-04 40 Troubleshooting
22 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 23
SEN02650-04 40 Troubleshooting
24 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 25
SEN02650-04 40 Troubleshooting
26 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 27
SEN02650-04 40 Troubleshooting
28 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 29
SEN02650-04 40 Troubleshooting
30 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 31
SEN02650-04 40 Troubleshooting
32 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 33
SEN02650-04 40 Troubleshooting
34 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 35
SEN02650-04 40 Troubleshooting
36 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 37
SEN02650-04 40 Troubleshooting
38 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 39
SEN02650-04 40 Troubleshooting
40 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 41
SEN02650-04 40 Troubleshooting
42 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 43
SEN02650-04 40 Troubleshooting
44 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 45
SEN02650-04 40 Troubleshooting
46 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 47
SEN02650-04 40 Troubleshooting
48 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 49
SEN02650-04 40 Troubleshooting
50 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 51
SEN02650-04 40 Troubleshooting
52 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 53
SEN02650-04 40 Troubleshooting
54 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 55
SEN02650-04 40 Troubleshooting
56 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 57
SEN02650-04 40 Troubleshooting
58 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 59
SEN02650-04 40 Troubleshooting
60 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 61
SEN02650-04 40 Troubleshooting
62 PC400, 450-8
40 Troubleshooting SEN02650-04
PC400, 450-8 63
SEN02650-04 40 Troubleshooting
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
64
SEN02651-03
PC400-8
PC400LC-8
PC450-8
PC450LC-8
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, 450-8 1
SEN02651-03 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 3
SEN02651-03 40 Troubleshooting
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
Pump resistor, lamp switch, swing holding brake
1 10A
release switch
Pump controller (solenoid power), Machine push-up
2 30A
switch
4 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 5
SEN02651-03 40 Troubleshooting
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.
6 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 7
SEN02651-03 40 Troubleshooting
8 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 9
SEN02651-03 40 Troubleshooting
10 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 11
SEN02651-03 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 13
SEN02651-03 40 Troubleshooting
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
• Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 sec-
onds after to notify completion of preheating (It stops flashing about 10 seconds after).
Related • If engine coolant temperature is below 20°C, automatic warm-up system operates and preheating
information monitor lights up for up to 30 seconds.
• Condition of starting switch (preheating) signal can be checked with the monitoring function.
(Code: 04500 Monitor input 1)
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.
14 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 15
SEN02651-03 40 Troubleshooting
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
16 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 17
SEN02651-03 40 Troubleshooting
18 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 19
SEN02651-03 40 Troubleshooting
Trouble • Machine monitor does not display at all when starting switch is turned ON.
Related
—
information
20 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 21
SEN02651-03 40 Troubleshooting
Trouble • Machine monitor does not display some items when starting switch is turned ON.
Related
—
information
Trouble • Contents of display by machine monitor are different from applicable machine.
Related
—
information
22 PC400, 450-8
40 Troubleshooting SEN02651-03
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)
PC400, 450-8 23
SEN02651-03 40 Troubleshooting
• 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.)
24 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 25
SEN02651-03 40 Troubleshooting
• 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)
26 PC400, 450-8
40 Troubleshooting SEN02651-03
• 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)
PC400, 450-8 27
SEN02651-03 40 Troubleshooting
• 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)
28 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 29
SEN02651-03 40 Troubleshooting
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related
—
information
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
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related
a If travel speed selection fails, proceed with troubleshooting No. H-22.
information
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
30 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 31
SEN02651-03 40 Troubleshooting
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)
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)
32 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 33
SEN02651-03 40 Troubleshooting
Trouble (3) When window washer switch is operated, window washer does not operate.
Related
information
34 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 35
SEN02651-03 40 Troubleshooting
36 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 37
SEN02651-03 40 Troubleshooting
Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01900 (Pressure Switch 1)
information
38 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 39
SEN02651-03 40 Troubleshooting
• Boom LOWER operation is not displayed normally by machine monitoring function (Special func-
Trouble
tions).
Related
• Monitoring code: 01900 (Output Switch 1)
information
40 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 41
SEN02651-03 40 Troubleshooting
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions).
Related
• Monitoring code: 01900 (Output Switch 1)
information
42 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 43
SEN02651-03 40 Troubleshooting
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions).
Related
• Monitoring code: 01900 (Output Switch 1)
information
44 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 45
SEN02651-03 40 Troubleshooting
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions).
Related
• Monitoring code:01901 (Output Switch 2)
information
46 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 47
SEN02651-03 40 Troubleshooting
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related
• Monitoring code: 01901 (Output Switch 2)
information
48 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 49
SEN02651-03 40 Troubleshooting
Trouble • Swing is not displayed normally by machine monitoring function (Special function).
Related
• Monitoring code: 01900 (Output Switch 1)
information
50 PC400, 450-8
40 Troubleshooting SEN02651-03
Circuit diagram related to right and left swing PPC oil pressure switches
PC400, 450-8 51
SEN02651-03 40 Troubleshooting
Trouble • Travel is not displayed normally by machine monitoring function (Special functions).
Related
• Monitoring code: 01900 (Output Switch 1)
information
52 PC400, 450-8
40 Troubleshooting SEN02651-03
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-8 53
SEN02651-03 40 Troubleshooting
• 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
• Monitoring code: 01901 (Output Switch 2)
54 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 55
SEN02651-03 40 Troubleshooting
Trouble • Service is not displayed normally by machine monitoring function (Special functions).
Related
• Monitoring code: 01901 (Output Switch 2)
information
56 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 57
SEN02651-03 40 Troubleshooting
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, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 59
SEN02651-03 40 Troubleshooting
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
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Wiring harness between F01-11 outlet – Resis-
Disconnection in wiring har- Max. 1 z
AC01 (male) (4) tance
ness
Wiring harness between AC01 (male) (7) – Resis-
3 (Disconnection in wiring or Max. 1 z
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
J04 – chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshoot-
Ground fault in wiring har- ing without turning starting switch ON.
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 AC01 (male) (7) – Resis-
Min. 1 Mz
P17 (female) (1) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
AC01 Voltage
Between (1) – (3) 20 – 30 V
60 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 61
SEN02651-03 40 Troubleshooting
E-30 Travel alarm does not sound or does not stop sounding 1
62 PC400, 450-8
40 Troubleshooting SEN02651-03
Circuit diagram related to travel PPC oil pressure switch and travel alarm
PC400, 450-8 63
SEN02651-03 40 Troubleshooting
64 PC400, 450-8
40 Troubleshooting SEN02651-03
PC400, 450-8 65
SEN02651-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
66
SEN02652-03
PC400-8
PC400LC-8
PC450-8
PC450LC-8
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, 450-8 1
SEN02652-03 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 3
SEN02652-03 40 Troubleshooting
4 PC400, 450-8
40 Troubleshooting SEN02652-03
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, 450-8 5
SEN02652-03 40 Troubleshooting
Presumed 2
Cause for presumed failure
cause and [Contents]
(The attached No. is for fil-
standard value • The standard values in normalcy by which to judge “Good”
3 ing and reference purpose
in normalcy or “No Good” about presumed causes.
only. It does not stand for
• References for making judgement of “good” or “No Good”
any priority.)
4
6 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 7
SEN02652-03 40 Troubleshooting
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
8 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 9
SEN02652-03 40 Troubleshooting
10 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 11
SEN02652-03 40 Troubleshooting
12 PC400, 450-8
40 Troubleshooting SEN02652-03
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
PC400, 450-8 13
SEN02652-03 40 Troubleshooting
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
14 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 15
SEN02652-03 40 Troubleshooting
Trouble • Hydraulic drift of work equipment is large. (2) Hydraulic drift of arm is large.
Related
• Set the working mode in P-mode before start.
information
16 PC400, 450-8
40 Troubleshooting SEN02652-03
Trouble • Hydraulic drift of work equipment is large. (3) Hydraulic drift of bucket is large.
Related
• Set the working mode in P-mode before start.
information
PC400, 450-8 17
SEN02652-03 40 Troubleshooting
18 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 19
SEN02652-03 40 Troubleshooting
20 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 21
SEN02652-03 40 Troubleshooting
22 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 23
SEN02652-03 40 Troubleshooting
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
• Set the working mode in P-mode before start.
information
24 PC400, 450-8
40 Troubleshooting SEN02652-03
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
Travel relief Max. 40 l/min
Final drive may have internal defect. Check it directly.
5 Defective final drive (It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.)
PC400, 450-8 25
SEN02652-03 40 Troubleshooting
26 PC400, 450-8
40 Troubleshooting SEN02652-03
Trouble • Upper structure does not swing. (2) Upper structure swings only in one direction.
Related
• Set the working mode in P-mode before start.
information
PC400, 450-8 27
SEN02652-03 40 Troubleshooting
28 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 29
SEN02652-03 40 Troubleshooting
• Upper structure overruns remarkably when (2) Swing acceleration or swing speed is low in only one
Trouble
it stops swinging. direction.
Related
• Set the working mode in P-mode before start.
information
30 PC400, 450-8
40 Troubleshooting SEN02652-03
PC400, 450-8 31
SEN02652-03 40 Troubleshooting
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
• Set the working mode in P-mode before start.
32 PC400, 450-8
40 Troubleshooting SEN02652-03
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, 450-8 33
SEN02652-03
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 11-10
34
SEN02653-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operations .............................................................................................................. 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 24
S-15 Abnormal noise is made....................................................................................................................... 25
PC400, 450-8 1
SEN02653-02 40 Troubleshooting
2 PC400, 450-8
40 Troubleshooting SEN02653-02
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
probable one by applying troubleshooting tools or
direct inspection.
Items listed in the [Questions] and [Check items]
and related to the [Causes] are marked with E, Q,
and w.
PC400, 450-8 3
SEN02653-02 40 Troubleshooting
Let us assume that when “Color of exhaust gas is black” occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
4 PC400, 450-8
40 Troubleshooting SEN02653-02
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in “Step 1” to “Step 3” in the figure below to narrow
the [causes] to lead to [troubleshooting].
PC400, 450-8 5
SEN02653-02 40 Troubleshooting
Defective injector
at maximum. This phenomenon does not indicate a trouble, however.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 PC400, 450-8
40 Troubleshooting SEN02653-02
PC400, 450-8 7
SEN02653-02 40 Troubleshooting
Degree of use of
Operated for long period EEE
machine
Condition of horn Horn does not sound Q Q w
when starting switch
is turned ON Horn volume is low w
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
q
Carry out troubleshooting in H-mode
Carry out troubleshooting in E-mode
out (*1)
Inspect flywheel ring gear directly q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
Troubleshooting
low
There is not voltage (20 – 30 V) between battery relay termi-
q
nal M and terminal E
Turn starting switch When terminal B and terminal C of starting switch are con-
q
OFF, connect cord, nected, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are con-
shooting at ON q
nected, engine starts
Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
—
—
Remedy
8 PC400, 450-8
40 Troubleshooting SEN02653-02
PC400, 450-8 9
SEN02653-02 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
10 PC400, 450-8
40 Troubleshooting SEN02653-02
c) Exhaust smoke comes out but engine does not start Cause
General causes why exhaust smoke comes out but engine does not start
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w w
cranked with starting out
motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Inspect air cleaner directly q
Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
PC400, 450-8 11
SEN02653-02 40 Troubleshooting
machine
Engine pick-up suddenly became worse Q w Q Q Q
Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and Mainte-
w w w
nance Manual
Engine oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained w w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
Q w
some cylinders is low
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q
Carry out troubleshooting for “EGR Valve Servo Error. (*1)” See *1 for failure code. q
When compression pressure is measured, it is found to be low q q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 PC400, 450-8
40 Troubleshooting SEN02653-02
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for code. q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Add
PC400, 450-8 13
SEN02653-02 40 Troubleshooting
Carry out troubleshooting for “EGR Valve Servo Error. (*1)” See *1 for failure code. q
Carry out troubleshooting for “Bypass Valve Servo Error. (*2)” See *2 for failure code. q
When air is bled from fuel system, air comes out q
Troubleshooting
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
14 PC400, 450-8
40 Troubleshooting SEN02653-02
Suddenly Q w Q Q Q
Power was lost
Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w Q
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low w w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
PC400, 450-8 15
SEN02653-02 40 Troubleshooting
Color of exhaust
Gradually became black w Q Q Q
gas
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
Dust indicator is red (if indicator is installed) w
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temper-
Q w
ature of some cylinders is low
When engine is cranked, interference sound is generated around turbocharger w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 PC400, 450-8
40 Troubleshooting SEN02653-02
Turbocharger
• Abnormal consumption of oil
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC400, 450-8 17
SEN02653-02 40 Troubleshooting
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates error even when oil temperature is high (if moni-
w Q
tor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items
Replace
Replace
Clean
Clean
Clean
—
Remedy
18 PC400, 450-8
40 Troubleshooting SEN02653-02
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *2 for failure code. q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error. (*2)” See *2 for fail-
q
ure code.
Check with monitoring function of the machine monitor. q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
PC400, 450-8 19
SEN02653-02 40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Cause
Remedy
20 PC400, 450-8
40 Troubleshooting SEN02653-02
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure
monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if monitor is Indicates pressure drop on slopes w
installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
—
Remedy
Add
PC400, 450-8 21
SEN02653-02 40 Troubleshooting
Degree of use
Operated for long period EE E E
of machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number
w Q
of bubbles appear, or coolant spurts back
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
22 PC400, 450-8
40 Troubleshooting SEN02653-02
PC400, 450-8 23
SEN02653-02 40 Troubleshooting
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged
w w
with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Inspect EGR cooler for leakage of coolant directly q
When compression pressure is measured, it is found to be low q
Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
24 PC400, 450-8
40 Troubleshooting SEN02653-02
machine
Condition of Gradually occurred Q Q
abnormal noise Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
PC400, 450-8 25
SEN02653-02 40 Troubleshooting
Replace
Correct
Adjust
Adjust
Remedy
26 PC400, 450-8
40 Troubleshooting SEN02653-02
PC400, 450-8 27
SEN02653-02
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
28
SEN02654-03
PC400LC-8
SEN02654-02
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400, 450-8 1
SEN02654-03 50 Disassembly and assembly
existing tools which were developed for other 4 :Weight of part or component
3. Circle mark Q in sketch column: is shown with the mark ([*1], [*2]...) which corre-
q The sketch of the special tool is presented in
sponds to the mark in "Removal" section.
q Common tools that are necessary for installation
the section of "Sketches of special tools".
q Part No. of special tools starting with
are described as [1], [2] ··· etc. and their part
79*T-***-****: means that they are not avail- numbers, part names and quantities are not de-
able from Komatsu in Japan (i.e. must be scribed.
q Marks shown in the "Installation" section stand
made locally).
for the following.
k :Precautions related to work safety
a :Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
2 PC400, 450-8
50 Disassembly and assembly SEN02654-03
assigned by setting forward the part number of are described as [1], [2] ··· etc. and their part
the existing tool. numbers, part names and quantities are not de-
Blank : Tools already available for other models. scribed.
They can be used without any modification. q The meanings of the symbols used in "Assem-
bly" section are as follows.
k : Precautions related to work safety
3. Circle markQin sketch column:
q The sketch of the special tool is presented in
a : Guidance or precautions for the work
2 : Type of coating material
the section of "Sketches of special tools".
3 : Tightening torque
q Part No. of special tools starting with
PC400, 450-8 3
SEN02654-03 50 Disassembly and assembly
4 PC400, 450-8
50 Disassembly and assembly SEN02654-03
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 q Used as lubricant/sealant when the radiator hos-
Gasket sealant
tions.
Molybdenum
PC400, 450-8 5
SEN02654-03 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR q Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
q Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
"W" facture)
Polyethyl- q Used as adhesive for glass.
Sika Japan,
20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Adhesive for cab glass
Sikaflex 256HV
tainer facture)
SUNSTAR Ecocart q Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- q Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
Caulking material
6 PC400, 450-8
50 Disassembly and assembly SEN02654-03
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 Distinction of new and existing special tools.
N………… Tools newly developed for this model. They have a new part number respectively.
R………… Tools prepared by redesigning the existing tools which were developed for other models. Each
of them has as new part number assigned by setting forward the part number of existing tool.
Blank:……Tools already available for other models and usable without any modification.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketch-
es of special tools).
Necessity
Symbol
Sketch
Q'ty
N/R
Component Part No. Part name Work items and remarks
PC400, 450-8 7
SEN02654-03 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q'ty
N/R
Component Part No. Part name Work items and remarks
8 PC400, 450-8
50 Disassembly and assembly SEN02654-03
Necessity
Symbol
Sketch
Q'ty
N/R
Component Part No. Part name Work items and remarks
PC400, 450-8 9
SEN02654-03 50 Disassembly and assembly
10 PC400, 450-8
50 Disassembly and assembly SEN02654-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
B. Stopper
PC400, 450-8 11
SEN02654-03 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
12 PC400, 450-8
50 Disassembly and assembly SEN02654-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
E4. Guide
PC400, 450-8 13
SEN02654-03 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
14 PC400, 450-8
50 Disassembly and assembly SEN02654-03
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
PC400, 450-8 15
SEN02654-03 50 Disassembly and assembly
© 2015 KOMATSU
All Rights Reserved
Printed in Japan 06-15 (01)
16
SEN02655-01
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02655-01 50 Disassembly and assembly
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 1 2 01010-81080 Bolt t 2
3 01643-31032 Washer t 2
Removal
k Disconnect the negative (–) terminal from bat-
tery.
1. Open the engine inspection cover.
2. Remove undercover (radiator, engine).
3. Remove cover (1).
4. Remove fan guard (2).
5. Remove air intake hose (3).
2 PC400, 450-8
50 Disassembly and assembly SEN02655-01
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]
PC400, 450-8 3
SEN02655-01 50 Disassembly and assembly
2) Align the tapped hole (hole for inserting 18. Remove the fuel supply pump mounting bolts
the removal bolt) of supply pump drive (23). Press the shaft of the pump using a tool and
gear to the mounting bolt hole of the cover remove the fuel supply pump assembly (24). [*5]
(cover (20) removed in step 15). a Take care not to drop the pump.
a Rotate the crankshaft to about the a Leave the tool applied until the pump is
middle (b) between the damper 2- installed. [*6]
5TOP and 3-4TOP and then inch the
crankshaft until correctly aligned to
the bolt hole.
a If the tapped hole on the drive gear
does not appear, rotate the crankshaft
one more round.
4 PC400, 450-8
50 Disassembly and assembly SEN02655-01
Installation [*4]
a Carry out installation in the reverse order to 3 Gear mounting nut:
removal. 127 – 147 Nm {13 – 15 kgm}
a Match the key and keyway to install.
[*1]
Tighten clamp (13) with the hand first, and then [*5]
tighten it permanently. 3 Joint bolt of pump side:
3 Clamp mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*6]
[*2] 2 Mounting bolt: Gasket sealant (LT-2)
k Don't correct high-pressure tube by bend-
ing it for re-use. q Fuel leak check
k Always use genuine clamp for fixing high- Refer to the paragraph on the "Checking fuel
pressure pipe. Strictly observe the tighten- circuit for leakage” in Testing and adjusting,
ing torque requirements. and check the fuel system for any leakage
accordingly.
a Check the following matters before installing
high-pressure pipe. If there is any abnormality, q Air bleeding
replace the high-pressure tube to prevent pos- Refer to the paragraph on the "Bleeding air
sible fuel leakage. from fuel circuit" in Testing and adjusting, and
bleed the air accordingly.
q Check the taper seal portion (between the tip
of section (a) and 2 mm from the end) of the
joint section for any vertical slit (b) and/or dent
(c) visually recognizable.
q Check part (d) (from the tip of the taper seal
portion to 2 mm from the end) for any stepped
wear (fatigue) your finger nail may catch.
[*3]
3 Joint bolt of tube (15):
25.5 – 34.3 Nm {2.5 – 3.5 kgm}
PC400, 450-8 5
SEN02655-01 50 Disassembly and assembly
Removal and installation of fuel 5. Remove clamp (4) and remove air intake tube
injector assembly 1 (5). [*1]
Removal
k Disconnect the negative (–) terminal from
battery.
1. Drain coolant.
6 Coolant: 36 l
6 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 7
SEN02655-01 50 Disassembly and assembly
19. Remove head cover (31). [*8] 22. Remove holder mounting bolt (40) of injector
(39) and then remove injector (39) along with
holder (41). [*11]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
8 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 9
SEN02655-01 50 Disassembly and assembly
[*8]
3 Head cover mounting bolt
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3) Insert holder (87) to injector (86). While holding
[*9] 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.
[*10]
a Tighten the mounting bolt of harness holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
[*11]
a Install the injector as follows.
a Check that the inside of the injector sleeve is
free from dirt.
1) Loosen the mounting bolt of common rail (85).
10 PC400, 450-8
50 Disassembly and assembly SEN02655-01
q Feed coolant
Feed coolant from the radiator coolant filler to
the specified level. Start the engine and allow
the coolant to circulate the piping. Check the
coolant level.
5 Coolant: 36 l
q Air bleeding
Refer to the paragraph on the “Bleeding air
from fuel circuit” in Testing and adjusting, and
bleed the air accordingly.
PC400, 450-8 11
SEN02655-01 50 Disassembly and assembly
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Seal puller
2 795-931-1100 q 1
assembly
A 1 795T-521-1140 Push tool t 1 N Q
3 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 9
12 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 13
SEN02655-01 50 Disassembly and assembly
[*1]
q Adjust the belt tension. For details, see Test-
ing and adjusting, “Checking and adjusting fan
belt and alternator belt tension” and “Checking
and adjusting air conditioner compressor belt
tension”.
14 PC400, 450-8
50 Disassembly and assembly SEN02655-01
Necessity
Symbol
Sketch
a If it is difficult to remove the seal, remove it
Q’ty
N/R
Part number Part name
according to the following procedure.
Seal puller
4 795-931-1100 q 1
assembly
1 795T-421-1340 Push tool t 1 N Q
5 2 01010-61635 Bolt t 3
3 01643-31645 Washer t 3
A 1 795-931-1220 Push tool t 1
6 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 3
1 795T-421-1320 Push tool t 1 N Q
7 2 01010-61645 Bolt t 3
3 01643-31645 Washer t 9
• A5: Press fitting of standard seal (with guide)
• A6, A7: Press fitting of sleeved seal
Removal of standard seal
Removal 1) Drill several holes about 3 mm in diameter
1. Remove hydraulic pump assembly by reading into engine rear oil seal (2).
the paragraph for the “Removal and installation a Remove all the chips.
of hydraulic pump assembly.” 2) Replace the tip of tool A4 with the drill-
type tip and insert it in one of the holes
2. Remove the damper. drilled in the above step.
3) Pull hammer [1] of tool A4 toward you and
3. Sling the flywheel (2) by leaving a flywheel remove the engine rear seal with impact
mounting bolt (1) unremoved. forces.
a Perform the above procedure at sev-
4. Sling the flywheel (2) to remove.
eral places so that the seal will not
4 Flywheel assembly: 60 kg slant.
k Since the sling [1] is held slanted when
the flywheel is lifted, care be taken for
the swinging of sling when the flywheel
assembly (2) is released.
PC400, 450-8 15
SEN02655-01 50 Disassembly and assembly
16 PC400, 450-8
50 Disassembly and assembly SEN02655-01
1. Set large inside diameter side (c) of guide (6) 4. Install tool A5-1 and tighten 3 bolts (A5-2)
of engine rear oil seal (2) to the end of crank- evenly until they stop to press fit engine rear oil
shaft (4). seal (2).
a Take care not to mistake the installed a Do not fit washers to bolts (A5-2).
direction. a When press fitting the seal, take care not
to damage the seal lip with the tool, etc.
PC400, 450-8 17
SEN02655-01 50 Disassembly and assembly
Procedure for installing sleeved seal 2. Apply sleeve (5) to sleeve and seal assembly
a Clean, degrease, and dry the contact face (2) to the end of crankshaft (4) and tighten 3
against the flywheel housing. bolts (A6-2) of tool A6-1 evenly to press fit
a Check that the end corners of the crankshaft, sleeve and seal assembly (2).
lip sliding surfaces, and housing are free from a Fit 1 washer (A6-3) each to bolts (A6-2),
flaws, burrs, rust, etc. and tighten them until the end of tool A6-1
a Do not apply oil or grease to the crankshaft touches the end of crankshaft (4).
and the inside cylinder of sleeve (5) and seal
lip (b) of the slash part. Wipe off the oil from the
crankshaft.
a Handle the engine rear oil seal (2) and sleeve
as an assembly and never separate them.
18 PC400, 450-8
50 Disassembly and assembly SEN02655-01
[*1]
a Tighten the flywheel mounting bolts in the
order shown in the following figure.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time : 147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
PC400, 450-8 19
SEN02655-01 50 Disassembly and assembly
Removal and installation of 5. 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
A8 790-331-1110 Wrench q 1
Removal
k Disconnect the negative (–) terminal from
battery.
1. Drain coolant.
6 Coolant: 36 l 6. Remove the clamp and disconnect hose (9)
between the radiator and the engine at the
2. Close the fuel stopper valve on the fuel tank. radiator side. [*2]
3. Disconnect connector P24 and overflow tube 7. Remove covers (6), (7), and fan guard (8).
(1) and remove the sub-tank (2).
20 PC400, 450-8
50 Disassembly and assembly SEN02655-01
9. Remove clamp (12) and two clamps (13) of 14. Disconnect the terminal of intake air heater
muffler. Shift the muffler (14) to remove the harness (19).
joint tube (15) and the muffler (14). a Disconnect the clamp, too.
15. Remove the air intake connector (20).
PC400, 450-8 21
SEN02655-01 50 Disassembly and assembly
17. Remove clamp (28), bolt (29) and brackets 20. Remove clamp (34) and boots (35) to remove
(30) to remove the housing complex (diffuser) 6 high-pressure injection tubes (36). [*4] [*8]
(31).
18. Remove brackets (behind the front hanger)
(32).
22 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 23
SEN02655-01 50 Disassembly and assembly
27. Remove exhaust manifold heat insulation covers 31. Remove spill tube (51). [*9]
(47).
32. Remove air vent tube (52). [*10]
29. Sling the turbocharger and exhaust manifold 34. Remove the injector harness as follows. [*12]
assembly (50), and remove the mounting bolts. 1) Fully loosen two capture nuts (55) on the
[*7] head of injector (54).
a Loosen nuts alternately.
30. Remove turbocharger and exhaust manifold 2) Loosen bolt (56) of harness fixing holder.
assembly by hoisting. 3) Disconnect injector harness (55a).
4 Turbocharger and exhaust manifold
assembly: 40 kg
24 PC400, 450-8
50 Disassembly and assembly SEN02655-01
35. Removal of rocker arm assembly (57) [*13] 38. Remove 12 crossheads (65). [*15]
1) Loosen locknut (58) and then loosen
adjustment screw (59) fully.
2) Remove mounting bolt (60) and then
rocker arm and shaft assembly (57).
PC400, 450-8 25
SEN02655-01 50 Disassembly and assembly
[*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}
[*6]
3 Lubrication tube sleeve nut:
40 – 44 Nm {4.1 – 4.5 kgm}
[*7]
Tighten the exhaust manifold assembly mounting
bolts in the order given below, then tighten other
bolts.
3 Exhaust manifold assembly mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
26 PC400, 450-8
50 Disassembly and assembly SEN02655-01
[*13]
1) Loosen locknut, then install rocker arm and
rocker shaft assembly.
3 Rocker shaft mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Remove the cover and adjust the valve clear-
ance.
Pointer is located under the cover.
q Valve clearance
Intake : 0.33 mm
Exhaust : 0.71 mm
a See the paragraph of “Adjusting valve clear-
ance” in the part for Testing and adjusting for
the valve clearance instructions.
[*8] 3 Rocker arm locknut:
a For details on and how to install the high-pres- 58.8 – 73.5 Nm {6 – 7.5 kgm}
s u r e tu be c o v e r, s ee P a r a gr a p h [ * 5] i n
"Removal and installation of fuel injector [*14]
assembly." a For the mounting instructions of injector and
holder, see the paragraph for the "Removal
High-pressure tube installation instructions and installation of fuel injector assembly."
a Don't correct high-pressure tube by bending it
for re-use. [*15]
1) Tighten high-pressure tube permanently. a Amply apply engine oil (EO30-CD) to cross-
3 Sleeve nut: head guide and crosshead top face.
39.2 – 49 Nm {4 – 5 kgm} a Adjust the crosshead according to the follow-
2) Temporarily tighten high-pressure clamp and ing procedure.
brackets all by hand. 1) Loosen the locknut and return the adjust-
3) Tighten high-pressure tube clamp perma- ment screw fully.
nently. 2) Holding the top of the crosshead lightly,
3 Clamp nut: tighten the adjustment screw while keep-
11.8 – 14.7 Nm {1.2 – 1.5 kgm} ing the crosshead in contact with the valve
4) Tighten bracket permanently. stem.
5) Install cover. 3) After the adjustment screw touches the
a Direct the slit to the side of cylinder head. valve stem, tighten it further by 20°.
4) Tighten the locknut at this position.
3 Locknut:
6) Temporarily install gate-type bracket and cover
(also working as clamp).
7) Tighten the cover permanently. 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
3 Cover mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm} [*16]
3 Rocker housing mounting bolt:
8) Tighten the gate-type bracket permanently.
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*9]
3 Spill tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*10]
3 Air vent tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*11]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*12]
a Tighten the capture nuts alternately.
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
PC400, 450-8 27
SEN02655-01 50 Disassembly and assembly
q Feed coolant
Feed coolant from the radiator coolant filler to
the specified level. Start the engine and allow
the coolant to circulate the piping. Check the
coolant level.
5 Coolant: 36 l
28 PC400, 450-8
50 Disassembly and assembly SEN02655-01
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]
7. Remove undercover.
8. Remove cover (11).
9. Disconnect the lower hose (12).
2. Drain coolant.
6 Coolant: 36 l
3. Disconnect connector (P24) and overflow tube
(3) and remove the sub-tank (4).
4. Remove the mounting bolt and then hoist the
engine hood assembly (5) to remove.
4 Engine hood: 200 kg
PC400, 450-8 29
SEN02655-01 50 Disassembly and assembly
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 again.
5 Coolant: 35 l
[*1]
3 Radiator-related hose clamp
(8) : 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(7) : 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
(6) : 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
30 PC400, 450-8
50 Disassembly and assembly SEN02655-01
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.
k Disconnect the negative (–) terminal from
battery.
PC400, 450-8 31
SEN02655-01 50 Disassembly and assembly
32 PC400, 450-8
50 Disassembly and assembly SEN02655-01
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 after cooler 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
Installation
q Carry out installation in the reverse order to
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, 450-8 33
SEN02655-01 50 Disassembly and assembly
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
engine hood assembly (3) to remove.
Necessity
4
Symbol
Sketch
Engine hood: 200 kg
Q’ty
N/R
Part number Part name
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.
6 Coolant: 36 l
2. Remove hydraulic oil tank strainer and stop oil
using tool C.
a When not using tool C, remove the drain
plug and drain oil from hydraulic oil tank
and the piping.
6 Hydraulic oil: 248 l
34 PC400, 450-8
50 Disassembly and assembly SEN02655-01
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.
PC400, 450-8 35
SEN02655-01 50 Disassembly and assembly
13. Remove fan (23). 17. Remove the terminal of intake air heater har-
ness (29) and clamps (30).
18. Remove the air intake connector (31).
36 PC400, 450-8
50 Disassembly and assembly SEN02655-01
20. Remove engine controller cover (35). 25. Disconnect return hose (41) and the clamp.
a Attach fuel stopper plug to the hose.
22. Remove harness clamp (38) at two locations. 27. Disconnect the car heater hose (43).
23. Remove grounding T11 (39).
24. Disconnect oil level sensor connector P44
(40).
PC400, 450-8 37
SEN02655-01 50 Disassembly and assembly
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).
38 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 39
SEN02655-01 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
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
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 again.
5 Coolant: 36 l
q Air bleeding
Refer to the paragraph on the "Bleeding air
from various parts" in Testing and adjusting.
40 PC400, 450-8
50 Disassembly and assembly SEN02655-01
PC400, 450-8 41
SEN02655-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN02656-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02656-02 50 Disassembly and assembly
Removal and installation of travel 4. Remove the 24 mounting bolts and lift off the
motor and final drive assembly 1 final drive assembly (6). [*1]
a Take care extremely not to damage the
nipple sealing faces of the hose joints.
Removal a When slinging the final drive assembly, do
1. Remove the sprocket. For details, see not use the tap hole for the cover.
“Removal and installation of sprocket”.
k Lower the work equipment to the 4 Final drive assembly: 700 kg
ground and stop the engine. Then,
loosen the hydraulic oil filler cap
slowly to release the internal pressure
of the hydraulic tank.
Installation
q Carry out installation in the reverse order to
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, 450-8
50 Disassembly and assembly SEN02656-02
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Disassembly
1. Draining oil
Remove the drain plug to drain the oil from the 4. No. 1 carrier assembly
final drive case. 1) Remove No. 1 carrier assembly (3).
6 Final drive case: 11 l
2. Cover
1) Place the final drive on block [1] and
remove the mounting bolts.
PC400, 450-8 3
SEN02656-02 50 Disassembly and assembly
4 PC400, 450-8
50 Disassembly and assembly SEN02656-02
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.
PC400, 450-8 5
SEN02656-02 50 Disassembly and assembly
4) Using puller [4], remove bearing (34) and 3) After installing the floating seal, measure
collar (33) together. protrusion (Ba to Bd) of the floating seal
a You can remove bearing (34) and col- from the housing at the measuring point
lar (33) without using puller [4] in shown in the figure below.
some cases. a Check that the difference between
maximum value (B-max) and mini-
mum value (B-min) of the values from
(Ba) to (Bd) is 1 mm or less.
B-max – B-min < 1 mm
a After installing the floating seal, thinly
apply power train oil to the sliding sur-
face.
2 Sliding surface:
Power train oil (TO30)
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) Press-fit bearings (28) and (29) by using
push tool.
6 PC400, 450-8
50 Disassembly and assembly SEN02656-02
PC400, 450-8 7
SEN02656-02 50 Disassembly and assembly
8 PC400, 450-8
50 Disassembly and assembly SEN02656-02
11) Install lock plate (23), fitting it to the motor iii) Insert pin (16).
spline. a After inserting the pin, caulk the
2 Threads of mounting bolt: pin part of the carrier.
Adhesive (LT-2) a After assembling the carrier assem-
3 Mounting bolt: bly, check that the gear (20) turns
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} smoothly.
4. Thrust washer
Install thrust washer (14) to No. 2 carrier
assembly (15).
PC400, 450-8 9
SEN02656-02 50 Disassembly and assembly
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.
10 PC400, 450-8
50 Disassembly and assembly SEN02656-02
7. No. 1 sun gear shaft Using eyebolts [2], install cover (1) and tighten
Install No. 1 sun gear shaft (12). the mounting bolts.
9. Cover
a After installing spacer (2), measure dis-
tance (j) from the top of planetary gear (9) q Refilling with oil
to the top of hub assembly (25) and check a Tighten the drain plug and add power train
the assembly condition. oil (TO30, or TOS0W30 for extremely cold
q Dimension (j): 1.2 mm district) through the oil filler.
a If dimension (j) is less than 1.2 mm or the
5 Final drive case: 11 l
top of planetary gear (9) is projected from
the top of hub assembly (25), they are not a After installing the final drive assembly to
assembled correctly. In this case, check the chassis, check the oil level again at
again. the specified position.
PC400, 450-8 11
SEN02656-02 50 Disassembly and assembly
Removal
k Release the residual pressure in the
hydraulic circuit. Refer to the “Releasing
residual pressure from hydraulic circuit”
section in the Testing and adjusting chap-
ter of this manual.
k Lower the work equipment to the ground
for oil filler cap on the fuel tank to release
the residual pressure inside the tank and 3. Lift and remove swing motor and swing
move the work equipment lock lever to the machinery assembly (6).
LOCK position. a When lifting the swing motor and swing
k Disconnect the negative (–) terminal from machinery assembly for removal, do so
battery. slowly so that the hoses and other parts
will not be damaged.
1. Disconnect five swing motor hoses (1) through a Take good care, when lifting the assembly,
(5). until the spigot joint portion is pulled out.
q (1): Between swing motor and control
4
valve (MA port)
Swing motor and swing machinery
q (2): Between swing motor and control
assembly: 550 kg
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.
q Air bleeding
Refer to the “Bleeding air from various parts” in
the Testing and adjusting chapter of this man-
ual.
12 PC400, 450-8
50 Disassembly and assembly SEN02656-02
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from
the swing machinery case.
6 Swing machinery case: Approx. 21 l
PC400, 450-8 13
SEN02656-02 50 Disassembly and assembly
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).
14 PC400, 450-8
50 Disassembly and assembly SEN02656-02
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.
PC400, 450-8 15
SEN02656-02 50 Disassembly and assembly
16 PC400, 450-8
50 Disassembly and assembly SEN02656-02
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.
ten the swelled part in advance.
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).
PC400, 450-8 17
SEN02656-02 50 Disassembly and assembly
18 PC400, 450-8
50 Disassembly and assembly SEN02656-02
PC400, 450-8 19
SEN02656-02 50 Disassembly and assembly
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)
20 PC400, 450-8
50 Disassembly and assembly SEN02656-02
PC400, 450-8 21
SEN02656-02
© 2015 KOMATSU
All Rights Reserved
Printed in Japan 06-15 (01)
22
SEN02657-04
PC400LC-8
SEN02657-02
HYDRAULIC EXCAVATOR
Shop Manual
PC400-8
PC400LC-8
PC450-8
PC450LC-8
Machine model Serial number
PC400-8 70001 and up
PC400LC-8 70001 and up
PC450-8 70001 and up
PC450LC-8 70001 and up
PC400, 450-8 1
SEN02657-04 50 Disassembly and assembly
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
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, 450-8
50 Disassembly and assembly SEN02657-04
PC400, 450-8 3
SEN02657-04 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q'ty
N/R
Part number Part name
1 791-630-1780 Installer t 1
G
2 791-601-1000 Oil pump t 1
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
parts). Take care that dirt will not stick to the a Using tool G2, fill the track roller assembly with
floating seal contact surfaces. oil and tighten the plug.
a Be sure to use the installer G1 to insert the 5 Track roller:
floating seal assembly in the housing. 280 - 310 cc (Single flange) (EO30-CD)
a After installing the floating seal, check that its 280 - 290 cc (Double flange) (EO30-CD)
slant is less than 1 mm and its projection (a) 3 Plug: 10 - 20 Nm {1 - 2 kgm}
is 5 - 7 mm.
4 PC400, 450-8
50 Disassembly and assembly SEN02657-04
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
Partnumber Part name
1 791-575-1520 Installer t 1
H
2 791-601-1000 Oil pump t 1
Disassembly
PC400, 450-8 5
SEN02657-04 50 Disassembly and assembly
6 PC400, 450-8
50 Disassembly and assembly SEN02657-04
6. Fit the O-ring, set support (3), install bolt (2), and
tighten nut (1).
PC400, 450-8 7
SEN02657-04 50 Disassembly and assembly
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring assembly assembly (1).
Necessity
1) Set tool J1 to recoil spring assembly (1).
Symbol
Sketch
k
Q'ty
N/R
Part number Part name Since the installed load of the spring is
large and dangerous, set the tool securely.
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
(686 kN {70 ton})
J 790-101-1102 Pump t 1
790-201-1500 Push tool kit t 1
790-201-1660 q Plate 1
2
790-101-5021 q Grip 1
01010-50816 q Bolt 1
Disassembly
8 PC400, 450-8
50 Disassembly and assembly SEN02657-04
2. Assembly of recoil spring assembly 4) Remove recoil spring assembly (1) from tool
1) Using tool J2, install dust seal (9) to cylinder J1.
(7).
3. Install piston assembly (2) to recoil spring
assembly (1).
2 Sliding part 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, 450-8 9
SEN02657-04 50 Disassembly and assembly
10 PC400, 450-8
50 Disassembly and assembly SEN02657-04
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
Part number Part name
2. Remove track shoes (2) on the right and left 6. Pull out pusher K.
sides of master pin (1) . [*1]
PC400, 450-8 11
SEN02657-04 50 Disassembly and assembly
Installation of track shoe 2 Apply grease to the contact faces of dust seal
q Carry out installation in the reverse order to ex- (5) and bushing (4) (all over the end face of
pansion. the dust seal or bushing) (parts marked Q).
Do not apply grease to the pars marked (X),
[*1] however.
2 Mounting bolt: Anti-seizure compound R: Detail of regular pin position
(MARUZEN MOLYMAX No. 2 or equiva- M: Detail of master pin position (Pins are not
lent)| inserted, however)
3 Mounting bolt: Tighten the 4 bolts first to 392
± 39 Nm {40 ± 4 kgm}. Check that the mating
faces are fitted, then retighten each bolt by
120 ± 10 °.
[*2]
a Adjust the tension of the track shoe. For detail,
see Testing and adjusting, "Checking and ad-
justing 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 its [*4]
projection (a) will be as follows. Set the track shoe and sprocket (4) as shown in
Dimension (a):4.4 ± 2 mm the following figure (on both right and left sides).
12 PC400, 450-8
50 Disassembly and assembly SEN02657-04
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, 450-8 13
SEN02657-04 50 Disassembly and assembly
[*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:
Gasket sealant (LG-6)
2 Threads of revolving frame mounting bolt:
Adhesive (LT-2)
14 PC400, 450-8
50 Disassembly and assembly SEN02657-04
3 Revolving frame mounting bolt 3) The tightening torque of the bolt tightened in
1. Tighten the bolts marked with A (at 4 places) 2) above must be 1,176 Nm {120 kgm} or
according to the following steps 1) - 3). larger.
1) Tighten each bolt to 392 Nm {40 kgm} first.
2) Then, tighten the bolt by 90 ± 5 °. 2. Tighten each bolt 208-25-71230 which is not
q Make a mark on the bolt head with a marked with A according to above steps 1) - 3).
marker pen (to check the angle). 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.
q Air bleeding
Bleed air from the travel motor. For details, see
Testing and adjusting, “leeding air from various
parts”.
PC400, 450-8 15
SEN02657-04 50 Disassembly and assembly
Special tools
Necessity
Symbol
Sketch
Q'ty
N/R
Part number Part name
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 tight ening torque for the counter-
weight mounting bolts.
3 Mounting bolt (Width across flats 65
mm):3,430 - 4,212 Nm {350 - 430 kgm} 2. Open engine inspection cover at the counter-
weight side.
Removal a Because the handle of the cover touches the
k Disconnect the cable from the negative (-) counterweight.
terminal of the battery.
3. Set eyebolt [1] to counterweight assembly (2).
1. Remove the accessories on the counterweight
according to the following procedure. 4. Remove 4 mounting bolts (10). [*1]
(Mirror specification)
1) Remove mirror (1).
2) Sling counterweight assembly (2).
16 PC400, 450-8
50 Disassembly and assembly SEN02657-04
PC400, 450-8 17
SEN02657-04 50 Disassembly and assembly
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.
[*1]
2 Threads of mounting bolt: Adhesive (LT-2)
3 Mounting bolt (width acrcss 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.(Maximam shim adjustment clear-
ance: 2mm)
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.
18 PC400, 450-8
50 Disassembly and assembly SEN02657-04
PC400, 450-8 19
SEN02657-04 50 Disassembly and assembly
© 2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
20
SEN02658-01
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02658-01 50 Disassembly and assembly
Removal and installation of center q (14): Center swivel joint (A port) – Left
swivel joint assembly 1 travel control valve (A2 port)
q (15): Center swivel joint (C port) – Right
travel control valve (A5 port)
Removal
k Release the remaining pressure in the 3. Pull out pin (16) on the side of center swivel
hydraulic circuit. For details, see Testing joint and remove the jam plate from the center
and adjusting, “Releasing residual pres- swivel joint.
sure from hydraulic circuit”.
k Disconnect the negative (–) terminal from
battery.
a Mark all the piping with tags to prevent mis-
takes in the mounting position when installing.
2 PC400, 450-8
50 Disassembly and assembly SEN02658-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
Install the center swivel joint facing in the direc-
tion shown in the diagram.
(The diagram shows the machine as seen from
above.)
q Bleeding air
Bleed the air from the travel motor. For details,
see Testing and adjusting, “Bleeding air from
various parts”.
PC400, 450-8 3
SEN02658-01 50 Disassembly and assembly
Special tools 3. Using tool M, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name 4. Remove seal (6) from swivel shaft (5).
790-101-2501 Push puller t 1 5. Remove O-ring (7) and slipper seal (8) from
790-101-2510 • Block 1 swivel rotor (4).
790-101-2520 • Screw 1
791-112-1180 • Nut 1
M 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
Disassembly
Assembly
1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
4 PC400, 450-8
50 Disassembly and assembly SEN02658-01
2. Drain the oil from the hydraulic tank. 10. Remove sensor (13).
6 Capacity of hydraulic tank: 335 l
11. Disconnect suction tube (14).
3. Remove control valve top cover (3). 12. Sling the hydraulic tank assembly temporarily
and remove 6 mounting bolts (15). [*1]
PC400, 450-8 5
SEN02658-01 50 Disassembly and assembly
[*1]
3 Mounting bolt:
254.2 – 308.9 Nm {25.0 – 31.5 kgm}
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
6 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 7
SEN02658-01 50 Disassembly and assembly
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)
8 PC400, 450-8
50 Disassembly and assembly SEN02658-01
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
PC400, 450-8 9
SEN02658-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
10 PC400, 450-8
50 Disassembly and assembly SEN02658-01
5. Set tool L2 to piston (1) for other seal (3) and Assembly
push it in with your hand slowly so that seal (3) q Apply engine oil to the sliding surfaces of the
will expand evenly. parts before installing.
a You may push in the seal to the flat part of q When installing spools (7) and (10) in the valve
the tool first, and then install the tool to the chamber, direct drilled holes (8) and (11)
piston and push in the seal further. toward cylinder ports (9) and (12).
PC400, 450-8 11
SEN02658-01 50 Disassembly and assembly
q Merge-divider valve
2 Mating face of merge-divider valve:
SEALEND 242 or equivalent
q Tighten the mounting bolts of the merge-
divider valve similarly to those of the control
valve covers.
12 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 13
SEN02658-01 50 Disassembly and assembly
Removal and installation of 2. Remove the hydraulic tank strainer. Using tool
hydraulic pump assembly 1 C, stop the oil.
a When not using tool C, remove the drain
plug to drain the oil from the hydraulic tank
Special tools and piping.
6 Hydraulic tank: 335 l
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
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.
14 PC400, 450-8
50 Disassembly and assembly SEN02658-01
9. Disconnect the following 2 pump wiring con- 11. Sling hydraulic pump assembly (18) tempo-
nectors. rarily and remove 12 mounting bolts (17).
q (6): V22 (PC-EPC solenoid valve)
Band color: Red
q (7): V21 (LS-EPC solenoid valve)
Band color: White
PC400, 450-8 15
SEN02658-01 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Hydraulic pump involute spline:
Anti-friction compound (LM-G)
2 Mating face of hydraulic pump case:
Gasket sealant (LG-6)
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
16 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 17
SEN02658-01 50 Disassembly and assembly
18 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 19
SEN02658-01 50 Disassembly and assembly
Necessity
20 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 21
SEN02658-01 50 Disassembly and assembly
22 PC400, 450-8
50 Disassembly and assembly SEN02658-01
Necessity
Symbol
Sketch
3) Pull out piston rod assembly (2).
Q’ty
N/R
Part number Part name
a Put a container under the cylinder to
receive oil.
Cylinder repair
1 790-502-1003 t 1
stand
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring (For boom
796-720-1680 q 1
and bucket)
Clamp (For boom
4 07281-01589 q 1
and bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
790-201-1702 Push tool kit t 1
• Push tool 4) Disassemble the piston rod assembly
790-201-1851 1
(For bucket)
according to the following procedure.
N • Push tool i) Set piston rod assembly (2) to tool N1.
790-201-1861 1
5 (For boom)
• Push tool
790-201-1871 1
(For arm)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Plate
6 790-201-1660 (For bucket)
1
• Plate
790-201-1670 1
(For boom)
• Plate
790-201-1680 1 ii) Remove piston assembly lock screw (3).
(For arm)
a This work is common to the boom,
arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75
PC400, 450-8 23
SEN02658-01 50 Disassembly and assembly
24 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 25
SEN02658-01 50 Disassembly and assembly
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 cyl-
inder.
26 PC400, 450-8
50 Disassembly and assembly SEN02658-01
6) Assemble piston assembly (4) according iii) Make a screw hole to install screw
to the following procedure. (3).
q When reusing the rod and piston a Apply a drill to the V-groove of
assembly (4) the threaded parts of piston (4)
i) Tighten piston assembly (4). Then, and rod (2) and make a hole.
using tool N2, tighten piston assem- a When making a hole on the cylin-
bly (4) until the screw holes are der (arm cylinder) having the bot-
aligned. tom cushion, make it around the
a Remove the burrs from the cushion plug.
threads with a file. q Dimensions of screw hole (mm)
Go to iv).
Tap drill diameter Tap to be used
10.3 12 x 1.75
2
q When replacing either or both of Threads of screw:
the rod and piston assembly (4) Adhesive (LOCTITE No. 262)
3 Screw:
with new ones
a Make a mark of the cushion plug
58.9 – 73.6 Nm {6 – 7.5 kgm}
position on the end of the rod having
the bottom cushion. v) Caulk the threaded part [1] by 4 places
q Perform this work for only the arm cyl- with a punch.
inder.
ii) Using the tool, tighten piston assem-
bly (4) until it reaches the end of the
rod.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check
that plunger (5) has some play.
q Perform this work for only the
boom and arm cylinders.
PC400, 450-8 27
SEN02658-01 50 Disassembly and assembly
3 Mounting bolt:
Cylinder
Tightening torque
name
Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm}
Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54.0 ± 8 kgm}
28 PC400, 450-8
50 Disassembly and assembly SEN02658-01
PC400, 450-8 29
SEN02658-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
30
SEN02659-01
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02659-01 50 Disassembly and assembly
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”.
2 PC400, 450-8
50 Disassembly and assembly SEN02659-01
PC400, 450-8 3
SEN02659-01 50 Disassembly and assembly
[*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
See Testing and adjusting, “Bleeding air from
various parts”.
4 PC400, 450-8
50 Disassembly and assembly SEN02659-01
PC400, 450-8 5
SEN02659-01 50 Disassembly and assembly
6 PC400, 450-8
50 Disassembly and assembly SEN02659-01
Installation
Anti-drop valve assembly
1. Install the anti-drop valve assembly (7) with the
bolts (6) (4 pieces).
2. Connect the tube (2) with the bolts (1) (4
pieces).
3. Connect the hoses (3), (4), and (5).
Air bleeding
q Bleed air from the hydraulic circuit. See Testing
and adjusting, “Bleeding air from hydraulic
circuit”.
PC400, 450-8 7
SEN02659-01 50 Disassembly and assembly
Removal and installation of anti- 2. Keep the arm cylinder and bucket cylinder at
the most retracted position. Turn the starting
drop valve assembly for arm 1 switch to OFF position to stop the engine.
k Place the machine on a level ground. 3. Turn the starting switch to ON position.
k Remove the anti-drop valve assembly from 4. Set the work equipment lock lever in FREE
the machine body, and then perform disas- position.
sembling of the anti-drop valve assembly.
k
5. Check that the work equipment is lowered to
High remaining pressure may remain in the
the ground by operating the work equipment
anti-drop valve assembly even after per-
control lever to the boom LOWER direction
forming normal releasing procedure. Be
fully to the stroke end.
sure to perform this procedure, and then
perform the releasing procedure.
k Anti-drop valve assembly is installed to the
high place. Set the scaffolding and wear the
safety belt always when performing this
work.
k When the arm cylinder moves only in one
direction inside the anti-drop valve for arm,
operate the cylinder to the stroke end in a
movable direction. Lower the bucket to the
ground, and then perform releasing the
remaining pressure.
If the arm cylinder is not at the stroke end
and it is removed from the cylinder of the
k
anti-drop valve, it is very dangerous.
Perform the step 3. to 5 in 15 seconds
a Wash around the anti-drop valve assembly in
after the engine stopped, since the bat-
order to prevent any dust or dirt from entering
tery charge in the PPC accumulator
it, and then perform the work.
lowers gradually.
k
a Install a plug or flange in the place where a
If the work equipment is not lowered or
hydraulic hose is disconnected to prevent oil
stops on the way, the battery charge of
from flowing out.
the PPC accumulator may be lowered.
a Check the connector numbers and installed
In such case, the remaining pressure
positions before disconnecting wirings and
cannot be released with this proce-
hoses, and record them.
dure.
a If the work equipment is lowered by its
own weight to the ground, the battery
Removal
charge of the PPC accumulator is normal.
Check for the function of PPC circuit accumula-
a PPC accumulator is a periodic inspection
tor.
item and an important periodic replace-
1. Set the arm cylinder and bucket cylinder to the ment part.
most retracted position (maximum arm OUT/
bucket DUMP position), and hold the work Releasing the remaining pressure in hydraulic
equipment at the height (a) off from the cylinder circuit
ground.
6. Start the engine.
(a): 1.5 m
7. Set the arm cylinder to the most extended
position (maximum arm IN position), and lower
the work equipment to the ground.
a Anti-drop valve is installed to the arm cyl-
inder, its head side. When the work equip-
ment is lowered with this posture, the oil in
the head side of the arm cylinder is
drained, and the remaining pressure is
low.
a Remaining oil amount on the head side is
low.
8 PC400, 450-8
50 Disassembly and assembly SEN02659-01
PC400, 450-8 9
SEN02659-01 50 Disassembly and assembly
Disassembly
Do not stand in a direction where the inside part
may jump out with the reaction force of the spring
when removing the bolts (1), (2), and the check
valve (3). Otherwise the inside part that will jump
out may hit your body.
10 PC400, 450-8
50 Disassembly and assembly SEN02659-01
PC400, 450-8 11
SEN02659-01
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 02-17 (01)
12
SEN02660-01
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02660-01 50 Disassembly and assembly
2 PC400, 450-8
50 Disassembly and assembly SEN02660-01
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.
PC400, 450-8 3
SEN02660-01 50 Disassembly and assembly
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
[*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}
4 PC400, 450-8
50 Disassembly and assembly SEN02660-01
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, 450-8 5
SEN02660-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
Part number Part name
sheets (glass sticking surfaces) of the opera-
Q’ty
N/R
tor's cab.
2 793-498-1210 Lifter (Suction cup) t 2 a Remove the adhesive and dam rubber to
X
3 20Y-54-13180 Stopper rubber t 2 a degree that they will not affect adhesion
of the new adhesive. Take care not to
scratch the painted surfaces.
(If the painted surfaces are scratched,
Removal
adhesion will be lowered.)
a Remove the window glass to be replaced
according to the following procedure. 2. Remove oil, dust, and dirt, etc. form the stick-
1. Using seal cutter [1], cut the adhesive between ing surfaces of operator cab and window glass
broken window glass (7) and operator cab with white gasoline.
(metal sheet)(8). a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at lease 5 minutes to dry.
6 PC400, 450-8
50 Disassembly and assembly SEN02660-01
PC400, 450-8 7
SEN02660-01 50 Disassembly and assembly
a Never apply the wrong primer. 4. Stick dam rubber (both-sided adhesive
If the glass primer, etc. is applied by mistake, tape)(6) along the inside edge of the glass
wipe it off with white gasoline. sticking section.
a Do not remove the release tape of dam
4) Apply the glass primer to the sticking sur- rubber on the glass sticking side before
faces of window glass (9). sticking the glass.
2 Glass primer: a When sticking the dam rubber, do not
Sunstar primer for glass 580 touch the cleaned surface to the utmost.
super or equivalent a Care should be taken not to float the dam
a Do not apply the primer more than 2 rubber of each sticking corner.
times.
(If it is applied more than 2 times, its
performance will be lowered.)
8 PC400, 450-8
50 Disassembly and assembly SEN02660-01
a Stick dam rubber (6a) additionally to 3) Stick dam rubber (6) for door lower win-
right side window glass (1). dow glass (3) to the position as shown in
q Positions to stick additional dam rub- the figure.
ber to the right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
PC400, 450-8 9
SEN02660-01 50 Disassembly and assembly
10 PC400, 450-8
50 Disassembly and assembly SEN02660-01
PC400, 450-8 11
SEN02660-01 50 Disassembly and assembly
a Since the window glass cannot be Sunstar primer for glass 580
removed and stuck again, stick it with super or equivalent
utmost caution. 2 Adhesive:
a Stick the glass within 5 minutes after SUNSTAR penguine seal 580
applying the adhesive. super “S” or “W” or equivalent
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber
closely.
a Press the corners of the window glass
firmly.
12 PC400, 450-8
50 Disassembly and assembly SEN02660-01
PC400, 450-8 13
SEN02660-01 50 Disassembly and assembly
14 PC400, 450-8
50 Disassembly and assembly SEN02660-01
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
PC400, 450-8 15
SEN02660-01 50 Disassembly and assembly
16 PC400, 450-8
50 Disassembly and assembly SEN02660-01
PC400, 450-8 17
SEN02660-01 50 Disassembly and assembly
18 PC400, 450-8
50 Disassembly and assembly SEN02660-01
8. Adjust the “Open” position of the front window 4) Loosen locknut (20) of right and left side of
assembly lock. rubber stoppers (18), and then pull back
1) After adjusting the “Close” position of the both rubber stoppers (18) so that they
front window assembly lock in steps 6 and won't contact with the fr ont window
7, raise the front window assembly to the assembly when it is in “Open” position.
ceiling.
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 l ock s ( 16) and ( 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 5) Loosen both sides of locknuts (22), and
4 – 7 mm. adjust the position of striker bolt (21).
a The position of limit switch (19) can- a Striker bolt (21): M10
n ot be ad ju st ed. The re for e , th e Inner diameter of plate (23): ø 14.5
“Open” position of the front window mm
assembly is decided within the range
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 1] Front window assembly (10) must be
“Open” position. pushing the limit switch backward for
4 – 7 mm (at “Open” position).
2] Working condition of lock (17).
PC400, 450-8 19
SEN02660-01 50 Disassembly and assembly
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).
20 PC400, 450-8
50 Disassembly and assembly SEN02660-01
[*2]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
PC400, 450-8 21
SEN02660-01 50 Disassembly and assembly
22 PC400, 450-8
50 Disassembly and assembly SEN02660-01
q Step 9 – 11 is optional (for breaker). 21. Remove clamps (24) and (25). [*2]
9. Disconnect the following PPC hoses from the 22. 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.
10. Disconnect connectors S11 (10) and S10 (11).
11. Disconnect connectors P13 (12) and V30 (13).
PC400, 450-8 23
SEN02660-01 50 Disassembly and assembly
24 PC400, 450-8
50 Disassembly and assembly SEN02660-01
Installation
q Installation is done in the reverse order of
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, Zexcel:
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.
PC400, 450-8 25
SEN02660-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
26
SEN02661-02
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02661-02 50 Disassembly and assembly
Removal and installation of air 8. Pull down opening and closing lever (8) of the
conditioner unit assembly outside air filter cover.
9. Remove outside air filter (9).
Removal
k Disconnect the negative (–) terminal from
the battery.
k Drain the coolant or disconnect the heater
hose when the coolant temperature in the
radiator is high, you may be scalded. In this
case, wait until the coolant temperature
lowers and then disconnect the heater
hose.
2 PC400, 450-8
50 Disassembly and assembly SEN02661-02
16. Remove ducts (20) and (21). 21. Disconnect connectors N10 (27) and AC01
a Cut tie-wrap. (28).
22. 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).
PC400, 450-8 3
SEN02661-02 50 Disassembly and assembly
[*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, Zexcel:
25. 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}
4 PC400, 450-8
50 Disassembly and assembly SEN02661-02
Installation
q Installation is done in the reverse order of
removal.
PC400, 450-8 5
SEN02661-02 50 Disassembly and assembly
6 PC400, 450-8
50 Disassembly and assembly SEN02661-02
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.
PC400, 450-8 7
SEN02661-02 50 Disassembly and assembly
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).
8 PC400, 450-8
50 Disassembly and assembly SEN02661-02
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.
PC400, 450-8 9
SEN02661-02 50 Disassembly and assembly
Removal
k Disconnect the negative (–) terminal from
the battery.
Installation
q Carry out installation in the reverse order to re-
moval
[*1]
3 Connectors (2) and (4):
3 ± 1 Nm {0.3 ± 0.1 kgm}
a Reference
q How to replace the seal of O-ring of power
3. Disconnect harness connector CE02 (2), CE03 source connector (4).
(3) and CE01 (4). [*1] Seal of O-ring:
a The connectors are locked with hexagonal 1010-074-0406 (NIHON-DEUTSCH Ltd.)
inside bolt (L6) (4 mm). or equivalent
10 PC400, 450-8
50 Disassembly and assembly SEN02661-02
PC400, 450-8 11
SEN02661-02
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 08-10
12
SEN02244-01
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02244-01 90 Diagrams and drawings
2 PC400, 450-8
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (1/2) PC400, 400LC-8, PC450, 450LC-8
PC400, 400LC-8, PC450, 450LC-8
SEN02244-01
PC400, 450-8 3
Hydraulic circuit diagram (2/2)
Hydraulic circuit diagram (2/2) PC400, 400LC-8, PC450, 450LC-8
PC400, 400LC-8, PC450, 450LC-8
SEN02244-01
PC400, 450-8 5
90 Diagrams and drawings SEN02244-01
PC400, 450-8 7
SEN02244-01 90 Diagrams and drawings
© 2017 KOMATSU
All Rights Reserved
Printed in Japan 02-17 (01)
8 PC400, 450-8
SEN02245-03
PC400-8
PC400LC-8
PC450-8
PC450LC-8
PC400, 450-8 1
SEN02245-03 90 Diagrams and drawings
2 PC400, 450-8
Electrical circuit diagram (1/5)
Electrical circuit diagram (1/5) PC400, 400LC-8, PC450, 450LC-8
SEN02245-03
PC400, 450-8 3
Electrical circuit diagram (2/5)
Electrical circuit diagram (2/5) PC400, 400LC-8, PC450, 450LC-8
SEN02245-03
PC400, 450-8 5
Electrical circuit diagram (3/5)
Electrical circuit diagram (3/5) PC400, 400LC-8, PC450, 450LC-8
SEN02245-03
PC400, 450-8 7
Electrical circuit diagram (4/5)
Electrical circuit diagram (4/5) PC400, 400LC-8, PC450, 450LC-8
SEN02245-03
PC400, 450-8 9
Electrical circuit diagram (5/5)
Electrical circuit diagram (5/5) PC400, 400LC-8, PC450, 450LC-8
SEN02245-03
PC400, 450-8 11
Connector list and stereogram
PC400, 400LC-8, PC450, 450LC-8
Connector list and stereogram PC400, 400LC-8, PC450, 450LC-8
PC400, 450-8 15
SEN02245-03
© 2016 KOMATSU
All Rights Reserved
Printed in Japan 10-16 (01)
16