PC450 7

SEBM033009
MACHINE MODEL SERIAL No.

PC400-7 50001 and up
PC400LC-7 50001 and up
PC450-7 20001 and up
PC450LC-7 20001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• PC400, 400LC, PC450, 450LC-7 mount the SAA6D125E-3 engine.

For details of the engine, see the 125-3 Series Engine Shop Manual.
© 2007
All Rights Reserved
Printed in Japan 09-07 (01)
00-1
(9)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ......................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 PC400/450(LC)-7
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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (9) 01-1 (8) 10-10 10-41 10-71 (8)

00-2 (3) 01-2 (8) 10-12 10-42 10-71-1 (8)
q 00-2-1 (9) 01-3 (8) q 10-13 (9) 10-43 10-71-2 (8)
q 00-2-2 (9) 01-4 (8) 10-14 10-44 10-71-3 (8)
q 00-2-3 (9) 01-5 (8) q 10-15 (9) 10-45 10-71-4 (8)
q 00-2-4 (9) 01-6 (8) q 10-16 (9) 10-46 (1) 10-71-5 (8)
q 00-2-5 (9) 01-7 (8) q 10-17 (9) 10-47 10-71-6 (8)
00-3 01-8 (8) 10-18 10-48 10-71-7 (8)
00-4 01-9 (8) q 10-19 (9) 10-50 (8) 10-71-8 (8)
00-5 01-10 (8) 10-20 10-51 (8) 10-71-9 (8)
00-6 01-11 (8) 10-21 10-52 (8) 10-71-10 (8)
00-7 01-12 (8) 10-22 10-53 (8) 10-71-11 (8)
00-8 01-13 (8) 10-23 10-54 (8) 10-71-12 (8)
00-9 01-14 (8) 10-24 10-55 (8) 10-71-13 (8)
00-10 01-15 (8) 10-26 (8) 10-56 (8) 10-71-14 (8)
00-11 01-16 (8) 10-27 10-57 (8) 10-71-15 (8)
00-12 01-17 (8) 10-28 10-58 (8) 10-71-16 (8)
00-13 10-29 (1) 10-59 (8) 10-71-17 (8)
00-14 10-30 10-60 (8) 10-71-18 (8)
00-15 10-1 (8) 10-31 10-61 (8) 10-71-19 (8)
00-16 10-2 10-32 (1) 10-62 (8) 10-71-20 (8)
00-17 10-3 10-33 10-63 (8) 10-71-21 (8)
00-18 10-4 10-34 10-64 (8) 10-71-22 (8)
00-19 10-6 10-35 10-65 (8) 10-71-23 (8)
00-20 10-7 10-36 (1) 10-66 (8) 10-71-24 (8)
00-21 10-7-1 (6) 10-37 10-67 (8) 10-71-25 (8)
00-22 10-7-2 (6) 10-38 10-68 (8) 10-71-26 (8)
10-8 10-39 10-69 (8) 10-71-27 (8)
10-9 10-40 10-70 (8) 10-71-28 (8)
PC400/450(LC)-7 00-2-1
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10-71-29 (8) 10-87 10-145 (1) 10-186 Q 20-17 (9)

10-71-30 (8) 10-88 10-146 10-187 Q 20-18 (9)
10-71-31 (8) 10-89 10-147 10-188 Q 20-19 (9)
10-71-32 (8) 10-90 (1) 10-148 (1) 10-189 Q 20-20 (9)
10-71-33 (8) 10-91 10-149 10-190
10-71-34 (8) 10-92 10-151 10-191 20-101 (7)
10-71-35 (8) 10-95 10-152 (1) 10-192 (1) 20-102 (1)
10-71-36 (8) 10-96 10-153 10-193 20-103 (1)
10-71-37 (8) 10-97 10-154 10-194 20-104 (1)
10-71-38 (8) 10-98 10-155 10-195 (1) 20-105 (1)
10-71-39 (8) 10-99 10-156 10-196 20-106 (1)
10-71-40 (8) 10-100 10-157 10-197 (4) 20-107 (1)
10-71-41 (8) 10-101 10-158 10-197-1 (4) 20-108 (1)
10-71-42 (8) 10-102 10-159 10-197-2 (4) 20-109 (1)
10-71-43 (8) 10-103 10-160 10-197-3 (4) 20-110 (1)
10-71-44 (8) 10-104 10-161 10-197-4 (4) 20-111 (1)
10-71-45 (8) 10-105 10-162 10-197-5 (4) 20-112 (1)
10-71-46 (8) 10-106 10-163 (1) 10-197-6 (4) 20-113 (1)
10-71-47 (8) 10-107 10-164 10-197-7 (4) 20-114 (1)
10-71-48 (8) 10-108 10-165 (1) 10-198 (8) 20-115 (1)
10-71-49 (8) 10-109 10-166 (1) 10-199 20-116 (1)
10-71-50 (8) 10-110 10-167 10-200 20-117 (1)
10-71-51 (8) 10-111 10-168 20-118 (1)
10-71-52 (8) 10-112 10-169 20-119 (1)
10-71-53 (8) 10-113 10-170 q 20-1 (9) 20-120 (1)
10-71-54 (8) 10-114 10-171 (1) q 20-2 (9) 20-121 (1)
10-71-55 (8) 10-115 10-172 q 20-3 (9) 20-122 (1)
10-72 10-136 (8) 10-173 q 20-4 (9) 20-123 (1)
10-74 10-137 10-174 (1) 20-5 (1) 20-124 (1)
10-75 10-137-1 (8) 10-175 20-6 (1) 20-125 (1)
10-76 (1) 10-137-2 (8) 10-176 (1) 20-7 (1) 20-126 (1)
10-77 (1) 10-138 (8) 10-177 20-8 (1) 20-127 (1)
10-78 10-139 10-178 20-9 (1) 20-128 (1)
10-79 (1) 10-139-1 (8) 10-179 20-10 (1) 20-129 (1)
10-80 10-139-2 (8) 10-180 (8) 20-11 (1) 20-130 (1)
10-82 10-140 10-181 (8) Q 20-12 (9) 20-131 (1)
10-83 10-141 10-182 (1) Q 20-13 (9) 20-132 (1)
10-84 10-142 10-183 (8) Q 20-14 (9) 20-133 (1)
10-85 10-143 (3) 10-184 (8) Q 20-15 (9) 20-134 (1)
10-86 10-144 10-185 (8) Q 20-16 (9) 20-135 (1)
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20-136 (1) 20-176 (1) 20-207 (1) 20-247 (1) 20-330 (1)
20-137 (1) 20-177 (1) 20-208 (1) 20-248 (1) 20-331 (1)
20-138 (1) 20-178 (1) 20-209 (1) 20-249 (1) 20-332 (1)
20-139 (1) 20-179 (1) 20-210 (1) 20-250 (1) 20-333 (1)
20-140 (1) 20-179-2 (7) 20-211 (1) 20-251 (1) 20-334 (1)
20-141 (1) 20-179-3 (7) 20-212 (1) 20-252 (1) 20-336 (1)
20-142 (1) 20-179-4 (7) 20-213 (1) 20-253 (1) 20-337 (1)
20-143 (1) 20-179-5 (7) 20-214 (1) 20-254 (1) 20-338 (1)
20-144 (1) 20-179-6 (7) 20-215 (1) 20-255 (1) 20-339 (1)
20-145 (1) 20-179-7 (7) 20-216 (1) 20-256 (1) 20-340 (1)
20-146 (1) 20-179-8 (7) 20-217 (4) 20-257 (1) 20-341 (1)
20-147 (1) 20-179-9 (7) 20-218 (4) 20-258 (1) 20-342 (1)
20-148 (1) 20-179-10 (7) 20-219 (4) 20-343 (1)
20-149 (1) 20-179-11 (7) 20-220 (4) 20-301 (1) 20-344 (1)
20-150 (1) 20-179-12 (7) 20-221 (1) 20-302 (1) 20-345 (1)
20-151 (1) 20-179-13 (7) 20-222 (1) 20-304 (1) 20-346 (1)
20-152 (1) 20-179-14 (7) 20-223 (4) 20-305 (1) 20-347 (1)
20-153 (1) 20-179-15 (7) 20-224 (1) 20-306 (1) 20-348 (1)
20-154 (1) 20-179-16 (7) 20-225 (1) 20-307 (1) 20-349 (1)
20-155 (1) 20-179-17 (7) 20-226 (1) 20-308 (1) 20-350 (1)
20-156 (1) Q 20-179-18 (9) 20-227 (1) 20-309 (1) 20-351 (1)
20-157 (1) Q 20-179-19 (9) 20-228 (1) 20-310 (1) 20-352 (1)
20-158 (1) Q 20-179-20 (9) 20-229 (1) 20-311 (1) 20-353 (1)
20-159 (1) 20-180 (1) 20-230 (1) 20-312 (1) 20-354 (1)
20-160 (1) 20-181 (1) 20-231 (1) 20-313 (1) 20-355 (1)
20-161 (1) 20-182 (1) 20-232 (4) 20-314 (1) 20-356 (1)
20-162 (1) 20-183 (1) 20-233 (4) 20-315 (1) 20-357 (1)
20-163 (1) 20-184 (1) 20-234 (1) 20-316 (1) 20-358 (1)
20-164 (1) 20-185 (1) 20-235 (1) 20-317 (1) 20-359 (1)
20-165 (1) 20-186 (1) 20-236 (1) 20-318 (1) 20-360 (1)
20-166 (1) 20-187 (1) 20-237 (1) 20-319 (1) 20-361 (1)
20-167 (1) 20-188 (1) 20-238 (1) 20-320 (1) 20-362 (1)
20-168 (1) 20-189 (1) 20-239 (1) 20-321 (1) 20-363 (1)
20-169 (1) 20-240 (1) 20-322 (1) 20-364 (1)
20-170 (1) 20-201 (1) 20-241 (1) 20-324 (1) 20-365 (1)
20-171 (1) 20-202 (1) 20-242 (1) 20-325 (1) 20-366 (1)
20-172 (1) 20-203 (1) 20-243 (1) 20-326 (1) 20-367 (1)
20-173 (1) 20-204 (1) 20-244 (1) 20-327 (1) 20-368 (1)
20-174 (1) 20-205 (1) 20-245 (1) 20-328 (1) 20-369 (1)
20-175 (1) 20-206 (1) 20-246 (1) 20-329 (1) 20-370 (1)
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20-372 (1) 20-413 (1) 20-525 (1) 20-603 (1) 20-716 (1)
20-373 (1) 20-414 (1) 20-526 (1) 20-604 (1) 20-717 (1)
20-374 (1) 20-415 (1) 20-527 (1) 20-605 (1) 20-718 (1)
20-375 (1) 20-416 (1) 20-528 (1) 20-606 (1) 20-719 (1)
20-376 (1) 20-417 (1) 20-529 (1) 20-607 (1) 20-720 (1)
20-377 (1) 20-418 (1) 20-530 (1) 20-608 (1) 20-721 (1)
20-378 (1) 20-420 (1) 20-531 (1) 20-609 (1) 20-722 (1)
20-379 (1) 20-421 (1) 20-532 (1) 20-610 (1) 20-723 (1)
20-380 (1) 20-422 (1) 20-533 (1) q 20-611 (9)
20-381 (1) 20-423 (1) 20-534 (1) 20-612 (1)
20-382 (1) 20-424 (1) 20-535 (1) 20-613 (1) 30-1 (2)
20-383 (1) 20-425 (1) 20-536 (1) 20-614 (1) 30-2 (2)
20-384 (1) 20-426 (1) 20-537 (1) 20-615 (1) 30-3 (2)
20-385 (1) 20-427 (1) 20-538 (1) 20-616 (1) 30-4 (2)
20-386 (1) 20-428 (1) 20-539 (1) 20-617 (1) 30-5 (2)
20-387 (1) 20-429 (1) 20-540 (1) 20-618 (1) 30-6 (5)
20-388 (1) 20-542 (1) 20-619 (1) 30-7 (5)
20-389 (1) 20-501 (1) 20-543 (1) 20-620 (1) 30-8 (2)
20-390 (1) 20-502 (1) 20-544 (1) 20-621 (1) 30-9 (2)
20-391 (1) 20-503 (1) 20-545 (1) 20-622 (1) 30-10 (5)
20-392 (1) 20-504 (1) 20-546 (1) 20-623 (1) 30-11 (2)
20-394 (1) 20-505 (1) 20-547 (1) 20-624 (1) 30-11-1 (5)
20-395 (1) 20-506 (1) 20-548 (1) 20-625 (1) 30-12 (2)
20-396 (1) 20-508 (1) 20-549 (1) 20-626 (1) 30-13 (2)
20-397 (1) 20-509 (1) 20-550 (1) 30-14 (2)
20-398 (1) 20-510 (1) 20-551 (1) 20-701 (1) 30-15 (2)
20-399 (1) 20-511 (1) 20-552 (1) 20-702 (1) 30-16 (2)
20-400 (1) 20-512 (1) 20-553 (1) 20-703 (1) 30-17 (2)
20-401 (1) 20-513 (1) 20-554 (1) 20-704 (1) 30-18 (2)
20-402 (1) 20-514 (1) 20-555 (1) 20-705 (1) 30-19 (2)
20-403 (1) 20-515 (1) 20-556 (1) 20-706 (1) 30-20 (2)
20-404 (1) 20-516 (1) 20-557 (1) 20-707 (1) 30-21 (2)
20-405 (1) 20-517 (1) q 20-558 (9) 20-708 (1) 30-22 (2)
20-406 (1) 20-518 (1) 20-559 (1) 20-709 (1) 30-23 (2)
20-407 (1) 20-519 (1) 20-560 (1) 20-710 (1) 30-24 (2)
20-408 (1) 20-520 (1) 20-561 (1) 20-711 (1) 30-25 (2)
20-409 (1) 20-521 (1) 20-562 (1) 20-712 (1) 30-26 (2)
20-410 (1) 20-522 (1) 20-713 (1) 30-27 (2)
20-411 (1) 20-523 (1) 20-601 (1) 20-714 (1) 30-28 (2)
20-412 (1) 20-524 (1) 20-602 (1) 20-715 (1) 30-29 (2)
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30-30 (2) 30-70 (2) 30-110 (2)

30-31 (2) 30-71 (2) 30-111 (2)
30-32 (2) 30-72 (2) 30-112 (2)
30-33 (2) 30-73 (5) 30-113 (2)
30-34 (2) 30-74 (2) 30-114 (2)
30-35 (2) 30-75 (2) 30-115 (2)
30-36 (2) 30-76 (2) 30-116 (2)
30-37 (2) 30-77 (2) 30-117 (2)
30-38 (2) 30-78 (2) 30-118 (2)
30-39 (2) 30-79 (2) 30-119 (2)
30-40 (2) 30-80 (2) 30-120 (2)
30-41 (2) 30-81 (2) 30-121 (2)
30-42 (2) 30-82 (2) 30-122 (2)
30-43 (2) 30-83 (2) 30-123 (2)
30-44 (2) 30-84 (2) 30-124 (2)
30-45 (2) 30-85 (2) 30-125 (5)
30-46 (2) 30-86 (2) 30-126 (5)
30-47 (2) 30-87 (2)
30-48 (2) 30-88 (2)
30-49 (2) 30-89 (2) q 90-1 (9)
30-50 (2) 30-90 (2) 90-3
30-51 (2) 30-91 (2) 90-5
30-52 (2) 30-92 (2) 90-7 (8)
30-53 (2) 30-93 (2) q 90-9 (9)
30-54 (2) 30-94 (2) 90-11 (8)
30-55 (2) 30-95 (2) 90-13 (8)
30-56 (2) 30-96 (2) 90-15 (8)
30-57 (2) 30-97 (2) 90-15-2 (8)
30-58 (2) 30-98 (2) 90-17
30-59 (2) 30-99 (2) q 90-19 (9)
30-60 (2) 30-100 (2) (90-21)
30-61 (2) 30-101 (2)
30-62 (2) 30-102 (2)
30-63 (2) 30-103 (2)
30-64 (2) 30-104 (2)
30-65 (2) 30-105 (2)
30-66 (2) 30-106 (2)
30-67 (2) 30-107 (2)
30-68 (2) 30-108 (2)
30-69 (2) 30-109 (2)
PC400/450(LC)-7 00-2-5
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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 danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ 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. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
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
(C)
(A) 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
00-16
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
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade 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 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
SPECIFICATION DRAWINGS ......................................................................................................................01- 2

SPECIFICATIONS ........................................................................................................................................01- 6
WEIGHT TABLE............................................................................................................................................01- 12
FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 16
PC400/450(LC)-7 01-1
(8)
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
BACKHOE SPECIFICATION
DIMENSIONS
Fixed gauge specification

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

Item Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7

C Overall width mm 3,490 3,490 3,490 3,490
H Length of track on ground mm 4,020 4,350 4,020 4,350
01-2 PC400/450(LC)-7
(8)
WORKING RANGES
Working range Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7
A Max. digging reach mm 12,025 12,025 12,005 12,005

B Max. digging depth mm 7,820 7,820 7,790 7,790
C Max. digging height mm 10,915 10,915 10,925 10,925
D Max. vertical wall depth mm 6,870 6,870 6,600 6,600
E Max. dumping height mm 7,565 7,565 7,625 7,625
F Min. dumping height mm — — — —
Max. reach at ground
G mm 11,820 11,820 11,800 11,800
level
PC400/450(LC)-7 01-3
LOADING SHOVEL SPECIFICATION
DIMENSIONS
Fixed gauge specification

PC400-7 PC400-7 PC400LC-7 PC400LC-7
Item Unit
Variable gauge Fixed gauge Variable gauge Fixed gauge
Overall width 3,490 3,440 3,490 3,440
C Overall width mm
2,990 — 3,090 —
(when retracted)
Length of track on
H mm 4,020 4,020 4,350 4,350
ground
01-4 PC400/450(LC)-7
(8)
WORKING RANGES
PC400-7 PC400-7 PC400LC-7 PC400LC-7

Working range Unit
Variable gauge Fixed gauge Variable gauge Fixed gauge
A Max. digging reach mm 8,660 8,660 8,660 8,660
Max. reach at ground
B mm 8,375 8,375 8,375 8,375
level
C Max. digging height mm 10,190 10,190 10,190 10,190
D Max. digging depth mm 3,045 3,045 3,045 3,045
Min. reach at ground
E mm 4,850 4,850 4,850 4,850
level
F Min. swing radius mm 4,535 4,535 4,535 4,535
PC400/450(LC)-7 01-5
(8)
GENERAL SPECIFICATIONS
SPECIFICATIONS
BACKHOE SPECIFICATIONS
PC400-7, PC400LC-7
PC400-7 PC400LC-7
Machine model Fixed gauge Variable Fixed gauge Variable

spec. gauge spec. spec. gauge spec.
Serial Number 50001 and up
Bucket capacity m3 1.4 1.4

Weight of machine kg 41,200 42,400 42,200 43,500
Max. digging depth mm 7,820 7,820
Working ranges
Max. vertical wall depth mm 6,870 6,870

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

Max. digging force kN {kg} 256.0 {26,100} 256.0 {26,100}
(using power max. function) kN {kg} (274.6 {28,000}) (274.6 {28,000})
Swing speed rpm 9.1 9.1
Swing max. slope angle deg. 20 20
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: 5.5 Lo: 3.0, Mi: 4.4, Hi: 5.5
Gradeability deg. 35 35
Ground pressure kPa {kg/cm }2
77.7{0.79} 79.9 {0.82} 73.9 {0.75} 65.3 {0.67}
Overall length mm 11,940 11,940 11,940 11,940

Overall width mm 3,340 3,490 3,440 3,590
(Track gauge when retracted) mm — 3,090 — 3,140
Overall width of track mm 3,340 3,490 3,340 3,590
Overall height mm 3,635 3,635 3,635 3,635
Overall height to top of machine mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320 1,320 1,320

Min. ground clearance mm 555 685 550 685
Tail swing radius mm 3,605 3,605 3,605 3,605
Min. swing radius of work equipment mm 4,735 4,735 4,735 4,735
Height of work equipment mm 9,210 9,210 9,210 9,210
at min. swing radius
Length of track on ground mm 4,020 4,020 4,350 4,350
Track gauge mm 2,740 2,890 2,740 2,890
Height of machine cab mm 2,920 2,920 2,920 2,920
Width of standard shoe mm 600 600 700 700
: The “Mi” mode is on the multi-monitor specification machine only
01-6 PC400/450(LC)-7
(8)
Machine model PC400-7 PC400LC-7
Model SAA6D125E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
No. of cylinders – bore × stroke mm 6 – 125 × 150
Piston displacement l {cc} 11.045 {11,045}
Flywheel horsepower kW/rpm {HP/rpm} 246.4/1,850 {330/1,850}

Performance
Max. torque Nm/rpm {kgm/rpm} 1,334/1,400 {136/1,400}

Engine
Max. speed at no load rpm 1,930

Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HPh} 203 {151}
Starting motor 24V, 7.5 kW

Alternator 24V, 35A
Battery 12V, 110 Ah × 2
Radiator core type ALW-4
Carrier roller 2 on each side
Undercarriage
Track roller 7 on each side 8 on each side
Assembly-type triple grouser, Assembly-type triple grouser,

Track shoe
45 on each side 48 on each side
Type × No. HPV160+160 (190), variable displacement, piston type x2

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

(with brake valve, parking brake): × 2
Hydraulic system
Swing motor KMF230ABE-5, Fixed displacement piston type

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

Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston

Inside diameter of cylinder mm 160 185 160
Diameter of piston rod mm 110 120 110
Stroke mm 1,570 1,820 1,270
Max. distance between pins mm 3,830 4,325 3,140
Min. distance between pins mm 2,260 2,505 1,870
Hydraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
PC400/450(LC)-7 01-7
(8)
PC450-7, PC450LC-7
PC450LC-7 PC450LC-7
Machine model Fixed gauge Variable Fixed gauge Variable

spec. gauge spec. spec. gauge spec.

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

Working ranges

Performance

(using power max. function) (275.5 {28,300}) (275.5 {28,300})
Swing max. slope angle deg. 17 17
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: 5.5 Lo: 3.0, Mi: 4.4, Hi: 5.5
Ground pressure kPa {kg/cm2} 80.5 {0.82} 82.9 {0.85} 76.5 {0.78} 78.1 {0.80}
Overall length (for transport) mm 12,040 12,040 12,040 12,040

Overall width mm 3,340 3,490 3,340 3,490
Overall height (for transport) mm 3,660 3,660 3,660 3,660
Overall height to top of machine mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320 1,320 1,320

Track gauge mm 2,740 2,890 2,740 2,890
: The “Mi” mode is on the multi-monitor specification machine only
01-8 PC400/450(LC)-7
(8)
Model SAA6D125E-3
Performance

Engine

Alternator 24 V, 35 A
Radiator core type ALW-4
Undercarriage

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

Control valve
Travel motor
Hydraulic motor
KMV200ADT-2, Variable displacement, piston type

Hydraulic system

Swing motor
KMF230ABE-5, Fixed displacement piston type
(with safety valve, holding brake, reverse rotation preventive valve): × 1
Boom Arm Bucket

Cylinder type Double-acting piston Double-acting piston Double-acting piston
Hydraulic cylinder
Inside diameter of cylinder mm 160 185 160

Outside diameter of piston rod mm 110 130 110
Stroke mm 1,570 1,985 1,270
Max. distance between pins mm 3,830 4,740 3,140
Min. distance between pins mm 2,260 2,755 1,870
PC400/450(LC)-7 01-9
(8)
Loading shovel specification
PC400, 400LC-7
PC400-7 PC400LC-7
Machine model Fixed gauge Variable gauge Fixed gauge Variable gauge
spec. spec. spec. spec.
Serial Number 50001 and up 50001 and up

Operating weight kg 43,100 44,300
Working ranges

Performance

(using power max. function)
Swing max. slope angle deg. 20.0 20.0
Travel speed km/h Lo: 3.2, Hi: 5.5 Lo: 3.2, Hi: 5.5
Ground pressure kPa {kg/cm2} 80.5 {0.82} 66.7 {0.68}
Overall length (for transport) mm 11,925 11,925 11,925 11,925
Overall width mm 3,340 3,490 3,440 3,590
(when track gauge retracted) — 3,090 — 3,140
(when track gauge retracted) — 2,990 — 3,090
Overall height (for transport) mm 3,355 3,355 3,355 3,355
Overall height to top of cab mm 3,265 3,265 3,265 3,265
Dimensions
Ground clearance of counterweight mm 1,320 1,320 1,320 1,320

Track gauge mm 2,740 2,890 2,740 2,890
01-10 PC400/450(LC)-7
(8)
Serial number 50001 and up
Model SAA6D125E-3
Performance
Engine

Alternator 24 V, 35 A
Radiator core type Aluminum wave type, 4 rows
Undercarriage

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

Hydraulic motor Control valve Hydraulic pump
KMV200ADT-2, Variable displacement, piston type

Travel motor
Hydraulic system
KMF230ABE-5, Fixed displacement piston type

Swing motor
(with safety valve, holding brake, reverse rotation preventive
valve): × 1
Boom Arm Bucket Bottom dump
Double-acting Double-acting Double-acting Double-acting
Type
Hydraulic cylinder
piston piston piston piston

Inside diameter of cylinder mm 160 185 135 130
Outside diameter of piston rod mm 110 120 95 90
Stroke mm 1,338 1,375 1,287 284
Max. distance between pins mm 3,837 3,615 3,322 1,091
Min. distance between pins mm 2,499 2,240 2,035 807
PC400/450(LC)-7 01-11
(8)
GENERAL WEIGHT TABLE
WEIGHT TABLE
PC400-7, PC400LC-7
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Engine assembly 1,500 1,500

• Engine 1,150 1,150
• Damper 14.7 14.7
• Hydraulic pump 210 210
Radiator, oil cooler assembly 195 195
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,297 3,297
Operator's cab 279 279
Operator's seat 35 35
Counterweight 9,220 9,500
Swing machinery (including swing motor) 526 526
Control valve (with service valve) 257 257
Swing motor 105 105
Travel motor 208 × 2 208 × 2
Center swivel joint 40 40
Fixed gauge Variable gauge Fixed gauge Variable gauge
specification specification specification specification
• Track frame assembly 10,173 11,367 10,965 11,934

• Track frame 5,506 6,766 6,077 7,096
• • Center frame — 3,229 — 3,229
• • Crawler frame — 1,754 × 2 — 1,921 × 2
• Swing circle 605 × 2 605 × 2
• Idler 230 × 2 230 × 2
• Idler cushion 338 × 2 338 × 2
• Carrier roller 32 × 4 32 × 4
• Track roller 72 × 14 72 × 16
• Final drive (including travel motor) 722 × 2 722 × 2
01-12 PC400/450(LC)-7
(8)
Unit: kg
Track shoe assembly

• Standard triple grouser shoe (600 mm) 4,470 4,760
• Wide triple grouser shoe (800 mm) 5,320 5,670
• Wide triple grouser shoe (900 mm) — 6,130
Boom assembly 3,290 3,290

Arm assembly 1,374 1,374
Bucket assembly 1,366 1,366
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 510 510
Bucket cylinder assembly 280 280
Link assembly 258 258
Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54
Arm pin 17 + 23 17 + 23
Bucket pin 38 × 2 38 × 2
Link pin 34 × 2 34 × 2
PC400/450(LC)-7 01-13
(8)
PC450-7, PC450LC-7
Unit: kg
Engine assembly 1,500 1,500

• Engine 1,150 1,150
• Damper 14.7 14.7
• Hydraulic pump 210 210
Radiator oil cooler assembly 195 195
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,402 3,402
Operator’s cab 279 279
Operator’s seat 35 35
Counterweight 9,220 9,220
Swing machinery 526 526
Control valve 257 257
Swing motor 105 105
Travel motor 208 × 2 208 × 2
Center swivel joint 40 40
Fixed gauge Variable gauge Fixed gauge Variable gauge
specification specification specification specification
• Track frame assembly 10,462 11,697 11,269 12,244

• Track frame 5,506 6,766 6,077 7,096
• • Center frame — 3,229 — 3,229
• • Crawler frame — 1,754 × 2 — 1,921 × 2
• Swing circle 605 605
• Idler 230 × 2 230 × 2
• Idler cushion 338 × 2 338 × 2
• Carrier roller 32 × 4 32 × 4
• Track roller 81 × 6, 72 × 8 81 × 8, 72 × 8
• Final drive (including travel motor) 722 × 2 722 × 2
01-14 PC400/450(LC)-7
(8)
Unit: kg
Track shoe assembly

• Wide triple grouser shoe (800 mm) — —
Boom assembly 3,380 3,380
Arm assembly 1,622 1,622
Bucket assembly 1,941 1,941
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 580 580
Bucket cylinder assembly 280 280
Link assembly 258 258
Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54
Arm pin 17 + 23 17 + 23
Bucket pin 38 × 2 38 × 2
Link pin 34 × 2 34 × 2
PC400/450(LC)-7 01-15
(8)
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS
01-16 PC400/450(LC)-7
(8)
GENERAL FUEL, COOLANT AND LUBRICANTS
Unit: l
PC400/400LC-7, PC450/450LC-7
Reservoir
Specified (l) Refill (l)
Engine oil pan 42 38
Swing machinery case 20.0 20.0
Final drive case 12 12
Damper case 1.07 1.07
Hydraulic system 472 248
Fuel tank 650 —
Cooling system 36 —
a For the HO46-HM, use the oil recommended by Komatsu.
PC400/450(LC)-7 01-17
(8)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE RELATED PARTS ..................... 10- 2
RADIATOR • OIL COOLER •
AFTERCOOLER ................................ 10- 3
POWER TRAIN ....................................... 10- 4
FINAL DRIVE .......................................... 10- 6
SPROCKET ............................................. 10- 11
SWING MACHINERY .............................. 10- 8
SWING CIRCLE ...................................... 10- 10
TRACK FRAME AND RECOIL SPRING . 10- 12
IDLER ...................................................... 10- 14
CARRIER ROLLER ................................. 10- 16
TRACK ROLLER ..................................... 10- 17
TRACK SHOE ......................................... 10- 18
HYDRAULIC PIPING DRAWING ............ 10- 22
HYDRAULIC TANK.................................. 10- 24
HYDRAULIC PUMP ................................ 10- 26
LS(PC)-EPC VALVE ................................ 10- 44
VARIABLE VOLUME VALVE .................. 10- 47
CONTROL VALVE .................................. 10- 50
CLSS ...................................................... 10-71-3
FUNCTIONS AND OPERATION
BY VALVE ......................................... 10-71-7
ATTACHMENT CIRCUIT
SELECTOR VALVE ......................... 10-71-49
HOLDING VALVE ................................. 10-71-51
SWING MOTOR ...................................... 10- 72
CENTER SWIVEL JOINT ........................ 10- 80
TRAVEL MOTOR..................................... 10- 82
VALVE CONTROL ................................... 10- 95
TRAVEL PPC SHUTTLE VALVE ............. 10- 96
WORK EQUIPMENT • SWING PPC
VALVE ................................................ 10-100
TRAVEL PPC VALVE .............................. 10-104
SERVICE PPC VALVE ............................ 10- 111
SOLENOID VALVE .................................. 10- 112
PPC ACCUMULATOR............................. 10- 114
RETURN OIL FILTER ............................. 10- 115
HYDRAULIC CYLINDER......................... 10-136
WORK EQUIPMENT ............................... 10-138
AIR CONDITIONER ................................ 10-144
ENGINE CONTROL ................................ 10-145
ELECTRONIC CONTROL SYSTEM ....... 10-151
MONITOR SYSTEM ................................ 10-178
7-SEGMENT MONITOR SYSTEM ....... 10-197-1
SENSOR ................................................. 10-198
PC400/450(LC)-7 10-1
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly Outline

2. Torsion spring 6. Muffler • The damper assembly is a wet type.
3. Stopper pin 7. Rear engine mount Oil capacity: 1.3 l
4. Friction plate 8. Front engine mount
10-2 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER
RADIATOR • OIL COOLER • AFTERCOOLER
1. Oil cooler 10. Condenser Specifications

2. Radiator 11. Fuel cooler
3. Radiator cap Radiator : ALW-4
4. Reservoir tank Oil cooler : CF40-1
5. Net
6. Shroud
7. Radiator inlet hose
8. Radiator outlet hose
9. Aftercooler
PC400/450(LC)-7 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Idler 7. Hydraulic pump (HPV190+190)

2. Center swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor (KMV 200ADT-2) 11. Swing motor (KMF230ABE-5)
6. Engine (SAA6D125-3E) 12. Swing circle
10-4 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
10-6 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 43)
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 18)
6. No. 1 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 98)
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 38)
Specification
Reduction ratio:
– 10 + 98 × 18 + 98 = –68.600
10 18
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 1 sun Standard clearance Clearance limit

14
gear and No. 1 planetary gear 0.15 – 0.54 1.10
Backlash between No. 1
15 0.18 – 0.66 1.30
planetary gear and ring gear
16 0.06 – 0.24 —
planetary carrier and motor
Backlash between No. 2 sun Replace
17 gear and No. 2 planetary 0.15 – 0.51 1.00
gear
Backlash between No. 2 plan-
18 0.17 – 0.60 1.20
etary gear and ring gear
19 planetary carrier and No. 2 0.15 – 0.54 —
sun gear
Amount of wear on sprocket
20 Repair limit: 6
tooth
Rebuild or
Standard size Repair limit replace
21 Width of sprocket tooth
90 87
PC400/450(LC)-7 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard size Repair limit

1 Wear of tooth tip
355 343
Build-up welding
2 Thickness of tooth root 20.8 14.8
or replace
3 Width of tooth 90 87
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
10-7-1 PC400/450(LC)-7
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET TOOTH SHAPE OF REAL DIMENSION
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(LC)-7 10-7-2
(6)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
10-8 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
13. Drain plug
Specification
Reduction ratio:
19 + 68 × 16 + 68 = 24.039
19 16
Unit: mm
Backlash between swing Standard clearance Clearance limit

14
motor shaft and No. 1 sun gear 0.18 – 0.28 —
Backlash between No. 1 sun
15 gear and No. 1 planetary 0.15 – 0.51 1.00
gear
16 0.17 – 0.60 1.10
17 planetary carrier and No. 2 0.40 – 0.75 1.20
sun gear
Replace
Backlash between No. 2 sun
18 0.16 – 0.55 1.00
gear and No. 2 planetary gear
19 0.17 – 0.60 1.10
Backlash between coupling
20 0.08 – 0.25 —
and swing pinion
Backlash between swing pin-
21 0.00 – 1.21 2.00
ion and swing circle
Clearance between plate
22 0.57 – 1.09 —
and coupling
Standard size Repair limit Apply hard
chrome plat-
Wear of swing pinion surface
23 0
ing, recondi-
contacting with oil seal 150 –0.100 — tion, or
replace
PC400/450(LC)-7 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 84) Specifications

2. Ball 84
Reduction ratio: – = –6.462
3. Swing circle outer race 13
Amount of grease: 33 l (G2-LI)
a. Inner race soft zone “S” position
b. Outer race soft zone “S” position
Unit: mm
Axial clearance of bearing Standard clearance Repair limit

4 Replace
(when mounted on chassis) 0.5 – 1.6 3.2
10-10 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
1. Idler • The dimensions and the number of track rollers

2. Track frame depend on the model, but the basic structure is
3. Carrier roller not different.
4. Final drive
5. Track roller • Number of track rollers
6. Track shoe
Model Q’ty
7. Center guard
8. Recoil spring PC400-7, 450-7 7
9. Front guard PC400LC-7, 450LC-7 8
10-12 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
Standard shoe
Model
PC400-7 PC400LC-7 PC450-7 PC450LC-7
Item
Shoe width 600 mm 700 mm 600 mm 600 mm
Link pitch 228 mm 228 mm 228 mm 228 mm
No. on track (one side) 46 (Pieces) 49 (Pieces) 46 (Pieces) 49 (Pieces)
Unit: mm
Standard
Tolerance Repair limit
size
+3
10 Vertical width of idler guide Track frame 148 –1 —
Rebuild or
Idler support 145 ±0.5 —
replace
+4
Track frame 302 –1 —
11 Horizontal width of idler guide
Idler support 297 — —

Free length Installation Installation Installation
Free length
12 Recoil spring × OD length load load Replace
239 kN
845.3 × 262 690 — —
{24,375 kg}
PC400/450(LC)-7 10-13
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-14 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Unit: mm
Repair limit
Outside diameter of protrud- Standard size
1
ing
704 —
2 Outside diameter of tread 660 648 Rebuild or
replace
3 Depth of tread 22 28
4 Total width 202 —
5 Width of tread 48.5 —
Tolerance Standard
Standard size
Clearance between shaft and Shaft Hole clearance
6
bushing
–0.120 +0.360
95 0.340 –0.507
–0.207 +0.220
Replace bushing
Tolerance Standard
Standard size
Interference between idler Shaft Hole interference
7
and bushing
+0.087 –0.027
102.6 0.064 –0.149
+0.037 –0.062
PC400/450(LC)-7 10-15
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

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 Interference Replace

Interference between shaft size Shaft Hole interference limit
6
and bushing
–0.250 +0.100 0.218 –
54 —
–0.280 –0.036 0.369
Interference between roller +0.117 +0.030 0.057 –
7 61 —
and bushing +0.087 0 0.177
Standard clearance Clearance limit
8 Axial clearance of roller
0.5 – 0.7 —
10-16 PC400/450(LC)-7
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Outside diameter of outer Standard size Repair limit

1
flange 240 —
Outside diameter of inner flange
2 237 —
(double flange)
3 Outside diameter of tread 200 188
4 Thickness of tread 56.2 50.2
5 Overall width 278 — Rebuild or
Singe flange 54.6 — replace
6 Width of tread
Double flange 51.6 —
Width of outer Singe flange 34.4 —

7
flange Double flange 34.4 —
Width of inner flange
8 23.0 —
(Double flange)
9 Axial play 0.4 – 1.0 —
Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
10
bushing
–0.250 +0.174 0.279 –
80 1.5
–0.350 +0.029 0.524 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
11
and bushing
+0.087 +0.022 0.015 –
87.6 —
+0.037 –0.013 0.097
PC400/450(LC)-7 10-17
(9)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
TRACK SHOE
a P portion shows the link of bushing press-fitting end.
10-18 PC400/450(LC)-7
Unit: mm

1 Link pitch
228.9 231.9 Reverse or
Standard size When turned replace
2 Bushing outside diameter
71 66.5
Adjust or
3 Thickness of bushing metal 12 7
replace
4 Link height
129 119 Repair or
replace
Thickness of link metal
5 34.5 24.5
(bushing press-fitting portion)
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
Inside
9 106
width
Overall Repair or
10 Link 51.6
width replace
Tread
11 44.8
width
12 Protrusion of pin 4.4
13 Protrusion of regular bushing 5.25
Adjust or
14 Overall length of pin 252
replace
15 Overall length of bushing 164.5
16 Thickness of spacer —
17 Bushing 118 – 304 kN {12 – 31 ton}
Press-fitting Regular
18 176 – 451 kN {18 – 46 ton} —
force pin
Master
19 137 – 284 kN {14 – 29 ton}
pin
: Dry type track link
PC400/450(LC)-7 10-19
(9)
Unit: mm
Tightening torque Additinal tightening

a. Regular (Nm {kgm}) angle (deg.)
link
Triple shoe 393±39 {40±4} 120±10
Shoe bolt Retighten
Tightening torque Additinal tightening Lower limit torque
20 b. Master (Nm {kgm}) angle (deg.) (Nm {kgm})
link
— — —
PC400-7, PC450-7: 46
No. of shoes (each side) —
PC400LC-7, PC450LC-7: 49
Tolerance Standard
Standard size
Interference between Shaft Hole interference
21
bushing and link
+0.494 +0.074
71 0.380 – 0.494
+0.454 0
Interference between regular +0.235 –0.218
22 47 0.303 – 0.515
pin and link +0.085 –0.280
Tolerance Standard
Standard size
Clearance between regular Shaft Hole clearance
23
pin and bushing
+0.235 +0.915 Adjust or
47 0.180 – 0.830
+0.085 +0.415 replace
Tolerance Standard
Standard size
Interference between master Shaft Hole interference
24 pin and bushing
+0.03 –0.218
47 0.218 – 0.310
0 –0.280
Tolerance Standard
Standard size
Clearance between master Shaft Hole clearance
25 pin and bushing
–0.2 +0.915
47 0.615 – 1.315
–0.4 +0.415
10-20 PC400/450(LC)-7
TRIPLE GROUSER SHOE
Unit: mm

1 Height
37 22
2 Thickness 13
3 33 Rebuild or
Length at of base
4 27 replace
5 25.5
6 Length at tip 17.5
7 23.5
PC400/450(LC)-7 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding 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
10-22 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING
PC400/450(LC)-7 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler cap Specifications

2. Breather Tank capacity: 335 l
3. Hydraulic tank Amount of oil inside tank: 248 l
4. Sight gauge
5. Strainer Pressure valve
6. Filter element • Relief cracking pressure: 16.7 ± 6.9 kPa
7. Strainer {0.17 ± 0.07 kg/cm2}
8. Bypass valve • Suction cracking pressure: 0 – 0.49 kPa
{0 – 0.005 kg/cm2}
• Bypass valve set pressure: 150 ± 30 kPa
{1.5 ± 0.3 kg/cm2}
Breather
• Intake valve set pressure: 2.0 ± 0.3 kPa
{0.02 ± 0.003 kg/cm2}
• Exhaust valve set pressure: 98 ± 14.7 kPa
{1.0 ± 0.15 kg/cm2}
10-24 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV160+160 (190)
1. Front main pump IM : PC mode selector current PENR : Rear pump control
2. Rear main pump ISIG : LS set selector current pressure detection port
3. LS valve PAF : Front pump delivery PLSF : Front load pressure input
4. PC valve PFC : Front pump delivery PLSFC: Front load pressure
5. LS-EPC valve pressure detection detection port
6. PC-EPC valve PAR : Rear pump delivery PLSR : Rear load pressure input
7. Variable volume valve PRC : Rear pump delivery PLSRC: Rear load pressure
pressure detection detection port
PBF : Front pump pressure input PS : Pump suction
PD1F : Case drain port PLSCR: LS set selector pressure
PENF : Front pump control detection port
pressure detection PM : PC set selector pressure
PBR : Rear pump pressure input detection port
PD2F : Drain plug PEPC : EPC basic pressure input
PD2R : Drain plug PDIR : Air bleeder
PEPB : EPC basic pressure
detection port
Outline
• This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-26 PC400/450(LC)-7
(8)
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
PC400/450(LC)-7 10-27
Function Structure
• The rotation and torque transmitted to the pump • Cylinder block (7) is supported to shaft (1) by a
shaft are converted into hydraulic energy, and spline, and shaft (1) is supported by the front and
pressurized oil is discharged according to the rear bearings.
load. • The tip of piston (6) is a concave ball, and shoe
• It is possible to change the discharge amount by (5) is caulked to it to form one unit. Piston (6) and
changing the swash plate angle. shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface A, and shoe (5) is
always pressed against this surface while sliding
in a circular movement.
Rocker cam (4) brings high pressure oil at cylin-
der surface B with cradle (2), which is secured to
the case, and forms a static pressure bearing
when it slides.
• Piston (6) carries out relative movement in the ax-
ial direction inside each cylinder chamber of cylin-
der block (7).
• The cylinder block seals the pressure oil to valve
plate (8) and carries out relative rotation. This sur-
face is designed so that the oil pressure balance is
maintained at a suitable level. The oil inside each
cylinder chamber of cylinder block (7) is sucked in
and discharged through valve plate (8).
10-28 PC400/450(LC)-7
Operation
1) Operation of pump
i Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
ii Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat surface
A moves as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F – E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged during
that stroke. On the other hand, the volume of
chamber F becomes larger, and as the vol-
ume becomes bigger, the oil is sucked in.
iii If center line X of rocker cam (4) is in line with
the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
umes E and F inside cylinder block (7)
becomes 0, so the pump does not carry out
any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
PC400/450(LC)-7 10-29
(1)
2) Control of discharge amount

• If the swash plate angle becomes larger,
the difference between volumes E and F be-
comes larger and discharge amount Q in-
creases.
• Swash plate angle is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement ( ) according to the signal pres-
sure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and rock-
er cam (4), which is supported by the cylin-
drical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the small
diameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).
10-30 PC400/450(LC)-7
LS VALVE
1. Plug PA : Pump port

2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port
6. Spool PPL : PC control pressure input port
7. Piston PSIG : LS mode selection pilot port
8. Sleeve
PC VALVE
1. Servo piston assembly PA : Pump port

2. Plug PA2 : Pump pressure pilot port
3. Pin PDP : Drain port
4. Spool PM : PC mode selector pressure pilot port
5. Retainer PPL : PC control pressure output port
6. Seat
7. Cover
8. Wiring
PC400/450(LC)-7 10-31
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
PLS (=PP – PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port pres-
sure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output, and pressure PSIG {called the LS selec-
tor pressure} from the proportional solenoid
valve enter this valve. The relationship between
discharge amount Q and differential pressure
PLS, (the difference between main pump
pressure PP and LS pressure PLS) (= PP –
PLS) changes as shown in the diagram at the
right according to LS pressure selector current
PSIG of the LS-EPC valve.
When PSIG changes between 0 and 1A, the set
pressure of the spring changes according to this,
and the selector point for the pump discharge
amount changes at the rated central valve
between 1.2 2.6 MPa {12 27 kg/cm2}.
(2) PC valve
When the pump discharge pressure PP1 (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In
this way, it carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump. The relationship between the average
of the front and rear pump discharge pressures
(average discharge amount of F, R pumps (PP1
+ PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to the
PC-EPC valve solenoid shown as a parameter.
The controller senses the actual speed of the
engine, and if the speed drops because of an
increase in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In
other words, when the load increases and the
engine speed drops below
the set value, the command current to the PC-
EPC valve solenoid from the controller
increases according to the drop in the engine
speed to reduce the pump swash plate angle.
10-32 PC400/450(LC)-7
(1)
OPERATION
(1) LS valve of the piston, so the swash plate is moved to the

1) When control valve is at neutral position minimum angle by the difference in the area of
• The LS valve is a three-way selector valve, with the piston (12).
pressure PLS (LS pressure) from the inlet port of
the control valve brought to spring chamber B,
and main pump discharge pressure PP brought
to port H of sleeve (8). The size of this LS pres-
sure PLS + force Z of spring (4) and the main
pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the
output pressure PSIG (the LS selection pres-
sure) of the EPC valve for the LS valve entering
port G also changes the position of spool (6).
(The set pressure of the spring changes).
• Before the engine is started, servo piston (12) is
pushed to the right. (See the diagram on the
right)
• When the engine is started and the control lever
is at the neutral position, LS pressure PLS is 0
MPa {0 kg/cm2}. (It is interconnected with the
drain circuit through the control valve spool.)
At this point, spool (6) is pushed to the right, and

port C and port D are connected. Pump pres-
sure PP enters the large diameter end of the
piston from port K and the same pump pressure
PP also enters port J at the small diameter end
PC400/450(LC)-7 10-33
2) Operation in increase direction for pump

discharge amount
• When the difference between the main pump • For this reason, the pressure at the large diame-
pressure PP and LS pressure PLS, in other ter end of servo piston (12) becomes drain pres-
words, LS differential pressure PLS, becomes sure PT, and pump pressure PP enters port J at
smaller (for example, when the area of opening the small diameter end, so servo piston (12) is
of the control valve becomes larger and pump pushed to the right. Therefore, the swash plate
PP drops), spool (6) is pushed to the left by the moves in the direction to make the discharge
combined force of LS pressure PLS and the amount larger. If the output pressure of the EPC
force of spring (4). valve for the LS valve enters port G, this pres-
• When spool (6) moves, port D and port E are sure creates a force to move piston (7) to the
joined and connected to the PC valve. When this right. If piston (7) is pushed to the right, it acts to
happens, the PC valve is connected to the drain make the set pressure of spring (4) weaker, and
port, so circuit D – K becomes drain pressure PT. the difference between PLS and PP changes
(The operation of the PC valve is explained lat- when ports D and E of spool (6) are connected.
er).
10-34 PC400/450(LC)-7
3) Operation in decrease direction for

pump discharge amount
• The following explains the situation if the servo • As a result, the swash plate moves in the direc-
piston (12) moves to the right (the discharge tion to make angle smaller.
amount becomes smaller). When LS differential • If LS selection pressure PSIG enters port G, it
pressure PLS becomes larger (for example, acts to make the set pressure of spring (4) weak-
when the area of opening of the control valve be- er.
comes smaller and pump pressure PP rises),
pump pressure PP pushes spool (6) to the right.
• When spool (6) moves, main port pressure PP
flows from port C and port D and from port K, it
enters the large diameter end of the piston.
• Main pump pressure PP also enters port J at the
small diameter end of the piston, but because of
the difference in area between the large diameter
end and the small diameter end of servo piston
(12), servo piston (12) is pushed to the right.
PC400/450(LC)-7 10-35
4) When servo piston is balanced

• Let us take the area receiving the pressure at the • At this point, the relationship between the area
large diameter end of the piston as A1, the area receiving the pressure at both ends of piston (12)
receiving the pressure at the small diameter end is A0 : A1 = 1:2, so the pressure applied to both
as A0, and the pressure flowing into the large di- ends of the piston when it is balanced becomes
ameter end of the piston as Pen. If the main PP : Pen = 2:1.
pump pressure PP of the LS valve and the com- • The position where spool (6) is balanced and
bined force of force Z of spring (4) and LS pres- stopped is the standard center, and the force of
sure PLS are balanced, and the relationship is spring (4) is adjusted so that it is determined when
A0 × PP = A1 × Pen, servo piston (11) will stop PP – PLS = 2.6 MPa {27 kg/cm2 }. However, if
in that position, and the swash plate will be kept PSIG (the output pressure of 0 2.9 MPa {0
at an intermediate position. (It will stop at a posi- 30 kg/cm2} of the EPC valve of the LS valve) is ap-
tion where the opening of the throttle from port D plied to port G, the balance stop position will
to port E and from port C to port D of spool (6) is change in proportion to pressure PSIG between
approximately the same.) PP – PLS = 2.6 1.2 MPa {27 12 kg/cm2}.
10-36 PC400/450(LC)-7
(1)
(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small
and pump pressures PP1 and PP2 are
low
i) Movement of PC-EPC solenoid (1)
• The command current from the pump con- • The size of command current X is deter-
troller flows to PC-EPC solenoid (1).This mined by the nature of the operation (lever
command current acts on the PC-EPC valve operation), the selection of the working
and outputs the signal pressure. When this mode, and the set value and actual value for
signal pressure is received, the force push- the engine speed.
ing piston (2) is changed. a Other pump pressure
• On the opposite side to the force pushing this This is the pressure of the pump at the oppo-
piston (2) is the spring set pressure of site end.
springs (4) and (6) and pump pressure PP1 For the F pump, it is the R pump pressure
(self pressure) and PP2 (other pump pres- For the R pump, it is the F pump pressure
sure) pushing spool (3). Piston (2) stops at a
position where the combined force pushing
spool (3) is balanced, and the pressure
(pressure of port C) output from the PC valve
changes according to this position.
PC400/450(LC)-7 10-37
ii) Action of spring

• The spring load of springs (4) and (6) in the • If the command circuit input to PC-EPC
PC valve is determined by the swash plate valve solenoid (1) changes further, the force
position. pushing piston (2) changes, and the spring
• If piston (9) moves to the right, spring (6) is load of springs (4) and (6) also changes ac-
compressed, and if it moves further to the cording to the valve of the PC-EPC valve so-
right, spring (6) contacts seat (5) and is fixed lenoid command current.
in position. In other words, the spring load is
changed by piston (9) extending or com-
pressing springs (4) and (6).
10-38 PC400/450(LC)-7
• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pres-
sure entering the LS valve becomes drain
pressure PT. If port E and port G of the LS
valve are connected (see (1) LS valve), the
pressure entering the large diameter end of
the piston from port J becomes drain pres-
sure PT, and servo piston (9) moves to the
left. In this way, the pump discharge amount
moves in the direction of increase.
• As servo piston (9) moves further, springs
(4) and (6) expand and the spring force be-
comes weaker. When the spring force be-
comes weaker, spool (3) moves to the right,
so the connection between port C and port D
is cut, and the pump discharge pressure
ports B and C are connected. As a result, the
pressure at port C rises, and the pressure at
the large diameter end of the piston also ris-
es, so the movement of piston (9) to the left
is stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC
valve solenoid and the pushing force created
by the pressures PP1 and PP2 acting on the
spool (3) are in balance.
PC400/450(LC)-7 10-39
b. When load on actuator is large and pump

discharge pressure is high
• When the load is large and pump discharge • If pump discharge pressure PP and PP2 in-
pressures PP1 and PP2 are high, the force creases further and spool (3) moves further
pushing spool (3) to the right becomes larger to the right, main pump pressure PP1 flows
and spool (3) moves to the position in the di- to port C and acts to make the discharge
agram above. When this happens, as shown amount the minimum. When piston (9)
in the diagram above, part of the pressurized moves to the right, springs (4) and (6) are
oil from port B flows out through port C compressed and push back spool (3). When
where the LS valve is actuated to port D, and spool (3) moves to the left, port C and port B
the pressurized oil flowing from port C to the are disconnected and port C and port D are
LS valve becomes approximately half of interconnected. As a result, the pressure at
main pump pressure PP. port C (= J) drops, and piston (9) stops mov-
• When port E and port G of the LS valve are ing to the right.
connected (see (1) LS valve), the pressure • The position in which piston (9) stops when
from port J enters the large diameter end of this happens is further to the right than the
servo piston (9), and servo piston (9) stops. position when pump pressures PP1 and PP2
are low.
10-40 PC400/450(LC)-7
• The relation of average pump pressure (PP1

+ PP2)/2 and the position of servo piston (9)
forms a bent line because of the double-
spring effect of springs (4) and (6). The rela-
tionship between average pump pressure
(PP1 + PP2)/2 and pump discharge amount
Q is shown in the figure at the right.
• If command voltage X sent to PC-EPC valve

solenoid (1) increases further, the relation-
ship between average pump pressure (PP1
+ PP2)/2, and pump discharge amount Q is
proportional to the pushing force of the PC-
EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC
solenoid (1) is added to the force pushing to
the left because of the pump pressure ap-
plied to the spool (3), so the relationship be-
tween the average pump pressure (PP1 +
PP2)/2 and Q moves from to in accord-
ance with the increase in X.
PC400/450(LC)-7 10-41
2) When pump controller is abnormal and • At this point, port C is connected to the drain
emergency pump drive switch is ON pressure of port D, and the large diameter
a. When load on main pump is light end of the piston of servo piston (9) also be-
• If there is a failure in the pump controller, turn comes the drain pressure PT through the LS
emergency pump drive switch ON to switch valve. When this happens, the pressure at
to the resistor side. In this case, the power the small diameter end of the piston is large,
source is taken directly from the battery. But so servo piston (9) moves in the direction to
if the current is used as it is, it is too large, so make the discharge amount larger.
use the resistor to control the current flowing
to PC-EPC valve solenoid (1).
• When this is done, the current becomes con-
stant, so the force pushing piston (2) is also
constant.
• If the main pump pressure PP1 and PP2 are
low, the combined force of the pump pres-
sure and the force of PC-EPC valve solenoid
(1) is weaker than the spring set force, so
spool (3) is balanced at a position to the left.
10-42 PC400/450(LC)-7
b. When main pump load is heavy

• In the same way as in the previous item, the diagram for the valve of the current sent
when the emergency pump drive switch is to the PC-EPC valve solenoid through the
ON, the command current sent to PC-EPC resistor.
valve solenoid (1) becomes constant. For The curve when the emergency pump drive
this reason, the force of piston (2) pushing switch is ON is curve , which is to the left
spool (3) is constant. of curve for when the pump controller is
• If main pump pressures PP1 and PP2 in- normal.
crease, 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 (See Fig. P).
• In this case, the pressure from port B flows
to port C, so servo piston (9) moves to the
right (to make the discharge amount smaller)
by the same mechanism as explained in item
2)-b, and stops at a position to the right of the
position when the load on the pump is light
(See Fig. Q). In other words, even when the
emergency pump drive switch is ON, the
curve for the pump pressure PP and dis-
charge amount Q is determined as shown in
PC400/450(LC)-7 10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS(PC)-EPC VALVE
LS(PC)-EPC VALVE
1. Body 5. Coil PSIG : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC: From self-reducing pressure
4. Rod valve
10-44 PC400/450(LC)-7
Function
• The EPC valve consists of the proportional sole-

noid portion and the hydraulic valve portion.
• When it receives signal current i from the pump
controller, it generates the EPC output pressure
in proportion to the size of the signal, and outputs
it to the LS valve.
Operation
1. When signal current is 0 (coil de-energized)

• When there is no signal current flowing from the
controller to coil (5), coil (5) is de-energized.
• For this reason, spool (2) is pushed to the left in
the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pressu-
rized oil from the main pump does not flow to the
LS valve.
At the same time, the pressurized oil from the LS
valve passes from port PSIG(PM) through port
PT and is drained to the tank.
PC400/450(LC)-7 10-45
2. When signal current is very small (coil ener-

gized)
• When a very small signal current flows to coil (5),
coil (5) is energized, and a propulsion force is
generated which pushes plunger (6) to the left.
• Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port PEPC to port
PSIG(PM).
• When the pressure at port PSIG(PM) rises and
the load of spring (3) + the force acting on sur-
face a of spool (2) becomes greater than the pro-
pulsion force of plunger (6), spool (2) is pushed
to the right. The circuit between port PEPC and
port PSIG(PM) is shut off, and at the same time,
port PSIG(PM) and port PT are connected.
• As a result, spool (2) is moved up or down until
the propulsion force of plunger (6) is balanced
with the load of spring (3) + pressure of port
PSIG(PM).
• Therefore, the circuit pressure between the EPC
valve and the LS valve is controlled in proportion
to the size of the signal current.
3. When signal current is maximum (coil ener-

gized)
• When the signal current flows to coil (5), coil (5)
is energized.
• When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6)
is also at its maximum.
• For this reason, spool (2) is completely pushed to
the left by push pin (4).
• As a result, the maximum flow of pressurized oil
from port PEPC flows to port PSIG(PM), and the
circuit pressure between the EPC valve and LS
valve becomes the maximum.
At the same time, port PT closes and stops the
oil from flowing to the tank.
10-46 PC400/450(LC)-7
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE
VARIABLE VOLUME VALVE
1. Block PM : To PC valve
2. Plug PT : To tank
3. Spring PEPC: From self-reducing pressure valve
4. Piston
PC400/450(LC)-7 10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE
Function
• This stabilizes the EPC output pressure.
Operation
• The output pressure from EPC flows to port PM,

and when the propulsion force of piston (4) be-
comes larger than the load of spring (3), piston
(4) is pushed to the left and the volume at port
PM increases.
When the propulsion force of piston (4) becomes
less than the load on spring (3), piston (4) is
pushed to the right and the volume at port PM
goes down.
10-48 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
• The control valve consists of a 7-spool valve (6-
spool valve + boom Hi, arm Hi valve) and a set of
service valves and bottom dump valve. A
merge-divider valve, a back pressure valve, a
boom drift preventive valve are installed to it.
• Since all the valves are assembled together with
connecting bolts and their passes are connected
to each other inside the assembly, the assembly
is compact and easy to maintain.
• With one spool provided for one work equipment,
this control valve is simple in construction.
Backhoe specification
A1: To bucket cylinder bottom PP2S: Pressure sensor mounting port
A2: To L.H. travel motor PPS1: To front pump control
A3: To boom cylinder bottom PPS2: To rear pump control
A4: To swing motor PR: To solenoid valve, PPC valve, and EPC valve
A5: To R.H. travel motor PS: From merge-divide solenoid valve
A6: To arm cylinder head PST: From travel junction valve solenoid valve
A-1: To boom cylinder bottom PX1: From 2-stage relief solenoid valve
A-2: To attachment 1 PX2: From 2-stage relief solenoid valve
A-3: To attachment 2 T: To tank
B1: To bucket cylinder head T1: To tank
B2: To L.H. travel motor TS: To tank
B3: To boom cylinder head TSW: To swing motor S-port (suction side)
B4: To swing motor
B5: To R.H. travel motor 1. 6-spool valve
B6: To arm cylinder bottom 2. Cover A
B-1: To arm cylinder bottom 3. Cover B
B-2: To attachment 1 4. Boom Hi and arm Hi valve
B-3: To attachment 2 5. Service valve 1
BP1: Boom raising PPC output pressure 6. Service valve 2
BP5: From 2-stage safety valve solenoid valve 7. Merge-divider valve
BP6: From attachment select solenoid valve 8. Boom drift preventive valve
P1: From bucket PPC and EPC valves 9. Quick return valve
P2: From bucket PPC and EPC valves 10. Boom Hi valve check valve
P3: From L.H. travel PPC valve
P5: From boom PPC and EPC valves
P7: From swing PPC and EPC valves
P9: From R.H. travel PPC valve
P11: From arm PPC and EPC valves
P-3: From service 1 PPC valves
PLS1: To front pump control
PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PP1S: Pressure sensor mounting port
10-50 PC400/450(LC)-7
(8)
General view
PC400/450(LC)-7 10-51
(8)
Sectional view
(1/5)
10-52 PC400/450(LC)-7
(8)
1. Pressure compensation valve (Arm OUT)

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

Free length × Installed Installed Installed
Free length
31 Spool return spring Outside diameter length load load
417 N 333 N
54.2 × 34.8 51.2
{42.5 kg}
— {34.0 kg}
393 N 315 N If damaged or
32 Spool return spring 54.5 × 34.8 51.2
{40.1 kg}
— {32.1 kg} deformed, replace
421 N 336 N spring.
{42.9 kg}
— {34.3 kg}
251 N 201 N
{25.6 kg}
— {20.5 kg}
417 N 333 N
{42.5 kg}
— {34.0 kg}
PC400/450(LC)-7 10-53
(8)
(2/5)
10-54 PC400/450(LC)-7
(8)
1. Suction safety valve (Arm OUT)

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

Free length × Installed
Installed load Free length Installed load
25 Suction valve spring Outside diameter length If damaged or
5.5 N 4.4 N deformed, replace
46.8 × 7.5 40.6
{0.56 kg}
— {0.45 kg} spring.
1.5 N 1.2 N
26 Check valve spring 11.5 × 4.6 8.5
{0.15 kg}
— {0.12 kg}
PC400/450(LC)-7 10-55
(8)
(3/5)
10-56 PC400/450(LC)-7
(8)
1. Unload valve
2. Safety valve (Boom RAISE)
4. Lift check valve
Arm valve
5. LS shuttle valve
6. Pressure compensation valve (IN)
7. Spool
8. Suction safety valve (IN)
9. Regeneration circuit check valve
10. Suction safety valve (OUT)
11. Pressure compensation valve (OUT)
R.H. travel valve

12. LS shuttle valve
13. Pressure compensation valve (FORWARD)
14. Spool
15. Suction valve (FORWARD)
16. Suction valve (REVERSE)
17. Pressure compensation valve (REVERSE)
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm

22 Spool return spring Outside diameter length If damaged or
50.0 × 14.4 42.0
{2.0 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
PC400/450(LC)-7 10-57
(8)
(4/5)
10-58 PC400/450(LC)-7
(8)
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divide valve (Main)
6. Return spring
Boom valve
7. Drift preventive valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. 2-stage suction safety valve (LOWER)
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
19. Spool
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
Unit: mm

29 Spool return spring Outside diameter length
157 N 126 N
46.6 × 21.8 33.0
{16.0 kg}
— {12.8 kg}
250 N 200 N
{25.5 kg}
— {20.4 kg}
{18.1 kg}
35.3 N 28.2 N spring.
{3.6 kg}
— {2.88 kg}
13.7 N 11.0 N
{1.4 kg}
— {1.12 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7 × 20.5 23.0
{5.1 kg}
— {4.08 kg}
PC400/450(LC)-7 10-59
(8)
(5/5)
10-60 PC400/450(LC)-7
(8)
Boom Hi and arm Hi valve
1. Boom Hi check valve

2. Quick return valve
4. Arm Hi spool
6. Boom Hi spool
Service valve 1
9. LS shuttle valve
10. Pressure compensation valve
11. Spool
12. 2-stage suction safety valve
13. Suction safety valve
Service valve 2
16. Spool
18. Unload valve

20. LS bypass plug
PC400/450(LC)-7 10-61
(8)
A1: To bucket cylinder bottom 1. 6-spool valve

A2: To L.H. travel motor 2. Cover A
A3: To boom cylinder bottom 3. Cover B
A4: To swing motor 4. Boom Hi and arm Hi valve
A5: To R.H. travel motor 5. Service valve 1
A6: To arm cylinder head 6. Bottom dump valve
A-1: To boom cylinder bottom 7. Merge-divider valve
A-2: To attachment 1 8. Boom drift preventive valve
A-3: To bottom dump cylinder head 9. Quick return valve
B1: To bucket cylinder head 10. Boom Hi valve check valve
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To arm cylinder bottom
B-2: To attachment 1
B-3: To bottom dump cylinder bottom
BP1: Boom raising PPC output pressure
BP5: From 2-stage safety valve solenoid valve
BP6: From attachment select solenoid valve
P1: From bucket PPC and EPC valves
P2: From bucket PPC and EPC valves
P-5: From bottom dump PPC valves
P-6: From bottom dump PPC valves
PLS1: To front pump control
PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PPS1: To front pump control
PPS2: To rear pump control
PR: To solenoid valve, PPC valve, and EPC valve
PS: From merge-divide solenoid valve
PST: From travel junction valve solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: To swing motor S-port (suction side)
10-62 PC400/450(LC)-7
(8)
General view
PC400/450(LC)-7 10-63
(8)
Sectional view
(1/5)
10-64 PC400/450(LC)-7
(8)
1. Pressure compensation valve (Arm OUT)

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

Free length × Installed Installed Installed
Free length
31 Spool return spring Outside diameter length load load
417 N 333 N
54.2 × 34.8 51.2
{42.5 kg}
— {34.0 kg}
{40.1 kg}
421 N 336 N spring.
{42.9 kg}
— {34.3 kg}
251 N 201 N
{25.6 kg}
— {20.5 kg}
417 N 333 N
{42.5 kg}
— {34.0 kg}
PC400/450(LC)-7 10-65
(8)
(2/5)
10-66 PC400/450(LC)-7
(8)
1. Suction safety valve (Arm OUT)

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

25 Suction valve spring Outside diameter length If damaged or
46.8 × 7.5 40.6
{0.56 kg}
1.5 N 1.2 N
{0.15 kg}
— {0.12 kg}
PC400/450(LC)-7 10-67
(8)
(3/5)
10-68 PC400/450(LC)-7
(8)
1. Unload valve
2. Safety valve (Boom RAISE)
4. Lift check valve
Arm valve
5. LS shuttle valve
6. Pressure compensation valve (IN)
7. Spool
8. Suction safety valve (IN)
10. Suction safety valve (OUT)
11. Pressure compensation valve (OUT)
R.H. travel valve

14. Spool
Swing valve
18. LS select valve
19. Pressure compensation valve (R.H.)
20. Spool
21. Pressure compensation valve (L.H.)
Unit: mm

22 Spool return spring Outside diameter length If damaged or
50.0 × 14.4 42.0
{2.0 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
PC400/450(LC)-7 10-69
(8)
(4/5)
10-70 PC400/450(LC)-7
(8)
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divide valve (Main)
6. Return spring
Boom valve
7. Drift preventive valve
8. LS shuttle valve
9. Pressure compensation valve (LOWER)
10. Spool
11. 2-stage suction safety valve (LOWER)
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
19. Spool
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
Unit: mm

29 Spool return spring Outside diameter length
157 N 126 N
46.6 × 21.8 33.0
{16.0 kg}
— {12.8 kg}
250 N 200 N
{25.5 kg}
— {20.4 kg}
{18.1 kg}
35.3 N 28.2 N spring.
{3.6 kg}
— {2.88 kg}
13.7 N 11.0 N
{1.4 kg}
— {1.12 kg}
5.9 N 4.71 N
{0.6 kg}
— {0.48 kg}
50.0 N 40.0 N
35 Piston return spring 30.7 × 20.5 23.0
{5.1 kg}
— {4.08 kg}
PC400/450(LC)-7 10-71
(1)
(5/5)
10-71-1 PC400/450(LC)-7
(8)
Boom Hi and arm Hi valve

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

16. Spool
18. Unload valve

20. LS bypass plug
PC400/450(LC)-7 10-71-2
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
Outline of CLSS
Features Configuration
CLSS stands for Closed center Load Sensing Sys- • CLSS is configured with variable capacity piston
tem, which has the following characteristics: pumps, control valves, and respective actuators.
• The hydraulic pump is configured with pump
• Fine control not influenced by load body, PC valve and LS valve.
• Controllability enabling digging even with fine
control
• Ease of compound operation ensured by flow di-
vider function using area of opening of spool dur-
ing compound operations
• Energy saving using variable pump control
10-71-3 PC400/450(LC)-7
(8)
Basic principle
1. Pump swash plate angle control
• The pump swash plate angle (pump delivery) is • The pump swash plate angle shifts toward the
controlled so that LS differential pressure maximum position if LS differential pressure
(EPLS) (the difference between pump pressure (EPLS) is lower than the set pressure of the LS
PP and control valve outlet port LS pressure valve (when the actuator load pressure is high).
PLS) (load pressure of actuator) is constant. If it becomes higher than the set pressure (when
• [LS differential pressure (EPLS) = 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.
• If it becomes higher than the set pressure (when
the actuator load pressure is low), the pump
swash plate angle shifts toward the minimum po-
sition.
LS differential pressure ( E PLS) and pump

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

pump”.
PC400/450(LC)-7 10-71-4
(8)
2. Pressure compensation control
• A pressure compensation valve is installed to the

outlet port side of the control valve to balance the
load.
• When actuators are operated together, the pres-
sure difference (EP) between the upstream (inlet
port) and downstream (outlet port) of the spool of
each valve becomes the same regardless the
size of the load (pressure).
• The flow of oil from the pump is divided (compen-
sated) in proportion to the area of opening (S1)
and (S2) of each valve.
10-71-5 PC400/450(LC)-7
(8)
3. System diagram
a The illustration shows actuator (7) in the merge

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

2. Rear pump 10. Tank circuit
3. Main relief valve 11. Valve
4. Unload valve 12. Spring
5. Merge-divider valve 13. LS bypass valve
6. Control valve 14. LS valve
7. Actuator 15. PC valve
8. Pump circuit
PC400/450(LC)-7 10-71-6
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FUNCTIONS AND OPERATION BY VALVE
FUNCTIONS AND OPERATION BY VALVE

Hydraulic circuit diagram and the name of valves
Backhoe specification
10-71-7 PC400/450(LC)-7
(8)
1. Arm valve 42. 2-stage suction safety valve

2. R.H. travel valve Set pressure: 1 stage: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
3. Swing valve 2 stage: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
4. Boom valve 43. Safety valve
5. L.H. travel valve Set pressure: 3
6. Bucket valve 8.2 ± 0.5 MPa {390 ± 5 kg/cm2}
7. Boom Hi valve
8. Arm Hi valve
9. Service valve 1
10. Service valve 2
11. Arm spool
12. R.H. travel spool
13. Swing spool
14. Boom spool
15. L.H. travel spool
16. Bucket spool
17. Boom Hi spool
18. Arm Hi spool
19. Service spool 1
20. Service spool 2
22. Variable pressure compensation valve
23. Suction valve
24. Check valve (for boom regeneration circuit)
25. Check valve (for arm regeneration circuit)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
35. Main relief valve (bucket side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
When digging force increased:
37.3 MPa {380 kg/cm2} (190l/min)
36. Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
37. Unload valve (bucket side)
Cracking pressure: 3.1 MPa {32 kg/cm2}
38. Unload valve (arm side)
Set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
Set pressure: 1 stage: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
2 stage: 21.1 ± 0.5 MPa {205 ± 5 kg/cm2}
PC400/450(LC)-7 10-71-8
(8)
10-71-9 PC400/450(LC)-7
(8)
1. Arm valve 42. 2-stage suction safety valve

2. R.H. travel valve Set pressure: 1 stage: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
3. Swing valve 2 stage: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
4. Boom valve 43. Safety valve
5. L.H. travel valve Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
6. Bucket valve 44. Suction safety valve
7. Boom Hi valve Set pressure: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
8. Arm Hi valve 45. Suction safety valve
9. Service valve 1 Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
10. Bottom dump valve 46. Suction safety valve
11. Arm spool Set pressure: 31.9 ± 0.5 MPa {325 ± 5 kg/cm2}
12. R.H. travel spool
13. Swing spool
14. Boom spool
16. Bucket spool
17. Boom Hi spool
18. Arm Hi spool
19. Service spool 1
20. Bottom dump spool
22. Variable pressure compensation valve
23. Suction valve
24. Check valve (for boom regeneration circuit)
25. Check valve (for arm regeneration circuit)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
35. Main relief valve (bucket side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
36. Main relief valve (arm side)
Set pressure:
34.8 MPa {355 kg/cm2} (160l/min)
37.3 MPa {380 kg/cm2} (190l/min)
37. Unload valve (bucket side)
38. Unload valve (arm side)
Set pressure: 1 stage: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
2 stage: 21.1 ± 0.5 MPa {205 ± 5 kg/cm2}
PC400/450(LC)-7 10-71-10
(8)
Unload valve
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function Operation
• Drains an oil discharge for the portion of the min- • 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. • Since the control valve is in neutral position,
• 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 be • Pressurized oil of pump circuit (3) stops at valve
P1). (2), and the pressure rises as no relief is availa-
• Since LS pressure is drained from the LS bypass ble.
valve, LS pressure C tank pressure C • When this pressure becomes larger than the
0 MPa {0 kg/cm2}. force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from
orifice (a) through port (c) and is drained to the
tank circuit (4).
• When actuated, LS pressure C tank pressure.
• Since the pump discharge pressure – LS circuit
pressure during unloading is larger than the
pump LS control pressure, the signal is output to
minimize the pump swash plate angle.
10-71-11 PC400/450(LC)-7
(8)
• During operation (a work within a scope of dis- 2. Operation of relief valve

charge by a minimum swash plate angle), the • When the cylinder reaches the stroke end, the
discharge pressure for the portion of minimum main relief valve opens.
pump swash plate angle is set to LS pressure + • The pump delivery (Q) is relieved to the
P1 pressure. tank.(See the system diagram)
• LS control differential pressure (EPLS) of dis- • The pump discharge pressure (PP) and LS pres-
charge for the portion of minimum swash plate sure (PLS) become approximately the same as
angle will be equal to P1 pressure. each has not flow at the upstream and down-
stream of the spool, and LS differential pressure
(EPLS) becomes 0 kg/cm2.
• As LS differential pressure (EPLS) is lower than
the LS set pressure of LS valve, LS valve is ac-
tuated to maximize the pump swash plate angle.
• Mechanically, operation of PC valve have the
prevalence to that of LS valve.
• The pump is held at a minimum swash plate an-
gle by the cut-off function of PC valve.
PC400/450(LC)-7 10-71-12
(8)
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
• Introduces the upstream pressure (spool meter-
in downstream pressure) of pressure compensa-
tion valve (3) and leads to LS shuttle valve (7) as
the LS pressure.
• Connected to actuator port (B) through valve (4),
and makes LS pressure C actuator load pres-
sure.
• Inlet pore (a) inside main spool (2) has a small di-
ameter concurrently serving as a throttle.
Operation
• When main spool (2) is operated, the pump pres-
sure enters port (c) through inlet pore (a) and is
led to the LS circuit.
• When the pump pressures rises to reach the load
pressure of port (B), check valve (5) opens and
the pressurized oil flows.
10-71-13 PC400/450(LC)-7
(8)
LS bypass valve
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
• Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to pre-
vent a sudden change of hydraulic pressure.
• 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).
• Effective LS differential pressure drops to im-
prove a dynamic stability of the actuator.
PC400/450(LC)-7 10-71-14
(8)
Pressure compensation valve

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

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

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

• High stress may occur when valve (2) collides
with valve chamber seat portion (C) if a high
peak pressure is generated in the actuator circuit
or repetitive peak pressure occurs continuously
(example: when using the breaker).
• To prevent this, a pressure compensation valve
with integrated valve (2) and piston (4) is used.
• With the present machine, this device is adopted
for the bucket valve (cylinder bottom) and the
service valve.
10-71-15 PC400/450(LC)-7
(8)
2. When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
• The pressure compensation valve closes under
LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equiv-
alent to the maximum pressure of other work
equipment.
• 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.
• Pump flow is divided according to the ratio of the
meter-in opening area.
Operation
• Spring chamber (E) is interconnected to port (D).
• 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).
• Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
PC400/450(LC)-7 10-71-16
(8)
3. Pressure compensation valve area ratio
Function
• The state of division changes according to the
area ratio of pressure compensation portion (A1)
and (A2). Area ratio = (A2)/(A1)
• If area ratio = 1 : the spool meter-in downstream
pressure will be equal to the maximum load pres-
sure, and the pressure will be divided according
to the opening area ratio.
• If area ratio = 1 or over : the spool meter-in
downstream pressure will be greater than the
maximum load pressure, and the pressure will be
divided smaller than the opening area ratio.
• 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.
10-71-17 PC400/450(LC)-7
(8)
Pressure compensation valve inner shuttle valve

1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B)
1. Hydraulic pump
2. Valve
3. Pressure compensation valve inner shuttle valve
4. Piston
Function
• Shuttle valve (3) is pushed to the right by port (A)
pressure and cuts off interconnection between
ports (A) and (C).
• 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(LC)-7 10-71-18
(8)
2. In the case of travel
Outline
• Since no holding pressure is generated at port
(A) of the travel circuit, a pressure compensation
valve without shuttle valve (3) is adopted.
10-71-19 PC400/450(LC)-7
(8)
Boom regeneration circuit

1. If the cylinder head pressure is lower than the bottom pressure (free fall, etc.)
1. Hydraulic pump
2. Boom spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
• Provides the regeneration circuit from the cylin- • 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 bot- inder bottom flows to drain circuit (B) from the
tom. notch of boom spool (2).
• 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).
• Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
PC400/450(LC)-7 10-71-20
(8)
2. If the cylinder head pressure is higher than the bottom pressure (digging work, etc.)
Function
• Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
10-71-21 PC400/450(LC)-7
(8)
Arm regeneration circuit

1. If the cylinder head pressure is higher than the bottom pressure
1. Hydraulic pump
2. Arm spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function Operation
• During arm digging, regeneration circuit provided • 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).
• On the other hand, remaining oil flows to regen-
eration circuit (C), opens check valve (6) and
flows to the cylinder bottom through circuit (D).
• Flow from regeneration circuit (C) and pump (1)
merges in circuit (E).
PC400/450(LC)-7 10-71-22
(8)
2. If the cylinder head pressure is lower than the bottom pressure
Function
• Check valve (6) provided to regeneration circuit
(C) closes to shut off the flow from the cylinder
bottom to the head.
10-71-23 PC400/450(LC)-7
(8)
Merge-divider valve 1
1. When flows from the pumps merge [if pilot pressure (PS) is OFF]
1. Main spool 5. LS circuit (bucket side)

2. Spring 6. LS circuit (bucket side)
3. LS spool 7. LS circuit (arm side)
4. Spring 8. LS circuit (arm side)
Function Operation
• Merges pressurized oil (P1) and (P2) discharged • Since pilot pressure (PS) is OFF, output pres-
from the two pumps or divides (to respective con- sure from PPC valve is 0 MPa {0 kg/cm2}.
trol valve group). • Main spool (1) is pressed to the right by spring (2)
• Merges and divides LS circuit pressure. and ports (E) and (F) are interconnected.
• Merges pressurized oil (P1) and (P2) discharged
from the two pumps at ports (E) and (F) and
sends to necessary control valve.
• 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.
• 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(LC)-7 10-71-24
(8)
2. When flows from the pumps are divided [if pilot pressure (PS) is ON]
Operation
• 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.
• Pressurized oil discharged from the two pumps
are sent to respective control valves.
P1 pressure: To bucket, L.H. travel, and boom
P2 pressure: To swing, R.H. travel, and arm
• 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.
• Forwards LS pressure led from each control
valve spool to LS circuits (5), (6), (7) and (8) to
respective control valves.
10-71-25 PC400/450(LC)-7
(8)
LS select valve
Function Operation
• Prevents high LS pressure from the swinging 1. If pilot pressure (BP) is OFF
from entering the LS circuit of work valves while • Since pilot pressure (BP) is OFF, piston (3) is
the swinging and work equipment are in compressed to the left by spring (2).
bined operation. • When swing-operated, swing LS pressure (P1)
• Prevents high pressure generated during swing enters port (A) after passing swing spool (5).
drive and improves operability of work equip- • Valve (1) is pressed to the left and ports (A) and
ment. (B) are interconnected.
• Swing LS pressure (P1) flows to LS shuttle valve
(8).
2. If pilot pressure (BP) is ON

• If pilot pressure (BP) is ON, BP pressure con-
tracts spring (2), and piston (3) shifts to the right.
• Valve (1) is pressed to the right and interconnec-
tion between ports (A) and (B) is closed.
• Swing LS pressure (P1) stops flowing to LS shut-
tle valve (8).
• If swing LS pressure (P1) rises, other LS circuits
are not affected.
a The illustration shows the state of simultaneous

operation of swinging and R.H. travel. [(BP)
pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
PC400/450(LC)-7 10-71-26
(8)
Self pressure reducing valve
Function
• 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
• Poppet (11) is pressed by spring (12) against the
seat and port (PR) is not connected to (TS).
• Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
• Valve (7) is pressed by spring (8) against the left
side and port (P2) is closed to (A2).
10-71-27 PC400/450(LC)-7
(8)
2.During neutral and when load pressure (P2) 3. When load pressure (P2) is high
is low • 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.
• Pressure (P2) increases to [(Ød area × P2 pres-
• Valve (7) is pressed to the closing direction of cir- sure) = force of spring (8) + (Ød area × PR pres-
cuit between ports (P2) and (A2) by spring (8) sure)], and valve (7) moves to the right to the
and under pressure (PR) (which is 0 MPa {0 kg/ stroke end.
cm2}). • As a result, opening between ports (P2) and (A2)
• When pressurized oil flows in from port (P2), a increases, and the pass resistance reduces, re-
balance is reached due to [(Ød area × P2 pres- ducing the engine horsepower loss.
sure) = force of spring (8) + (Ød area × PR pres- • When pressure (PR) rises above the set pres-
sure)]. sure, poppet (11) opens.
• Adjusts valve (7) opening to keep pressure (P2) • Pressurized oil flows from port (PR) to orifice (a)
at a constant level over pressure (PR). in spool (14), then flows to seal drain port (TS)
• When pressure (PR) rises above the set pres- from poppet (11) opening.
sure, poppet (11) opens. • Differential pressure is generated before and af-
• 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).
• Differential pressure is generated before and af- • 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).
• 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(LC)-7 10-71-28
(8)
4. When abnormally high pressure is gener-

ated
• If pressure (PR) of self pressure reducing valve
becomes abnormally high, ball (16) contracts
spring (15) and becomes separated from the
seat.
• Allows the pressurized oil to (TS) from port (PR)
and lowers pressure (PR).
• Protects PPC valve, solenoid valve and other de-
vices from abnormal pressure.
10-71-29 PC400/450(LC)-7
(8)
Travel junction valve

1. When pilot pressure is turned ON
Function Operation
• This valve connects the L.H. and R.H. travel cir- • 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. • Junction circuit between port (PTL) (L.H. travel
• 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(LC)-7 10-71-30
(8)
2. When pilot pressure is turned OFF
Operation
• If pilot pressure (PST) from the solenoid valve is • 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.
10-71-31 PC400/450(LC)-7
(8)
Travel PPC shuttle valve

1. When travel lever is in neutral
Function Operation
• Regulates flow to each cylinder by controlling the • The oil in stroke regulation signal chamber (a) is
stroke of each spool of the boom, arm, and buck- drained through orifices (5) and (6) of pistons (3)
et using the pilot pressure of travel PPC valve and (4) in the travel spring case and the travel
while climbing a steep grade, raising the boom, PPC valve.
digging with arm, dumping, bucket-digging or op- • When operated for boom raising (or arm digging,
erating dump. dumping, bucket digging, dumping), spool (1)
• 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(LC)-7 10-71-32
(8)
2. When traveling
Operation
• If the right travel lever is set in the reverse (or for-
ward) direction, pilot pressure from the PPC
valve presses spool (7) to the left (or right).
• Spool (7) pushes piston (3) to close orifice (5)
and shut off stroke regulation signal chamber (a)
and the drain circuit of the travel PPC valve.
• 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.
• When operated for boom raising (or arm in, out,
bucket curl, dump), spool (1) moves to the left.
• Maximum stroke of the spool is limited to (st1) for
the amount of movement (st2) of piston (8) to the
right.
10-71-33 PC400/450(LC)-7
(8)
Boom drift preventive valve

1. When raising boom
Function
• 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
• When the boom is raised, pressurized oil from
the control valve works on the ring-shaped area
(S)[= Ø(d1) area – Ø(d2) area] caused by the dif-
ference between outside diameter (d1) of poppet
(5) and seat diameter (d2) to move it to the left.
• Contracts spring (4) and poppet (5) moves to the
left.
• 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(LC)-7 10-71-34
(8)
2. When the boom is in neutral
Operation
• Moves the lever to neutral with the boom raised.
• Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
• Pressurized oil from the control valve and the
holding pressure of the boom cylinder bottom are
shut off.
• 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.
• The sum of this force and the force of spring (4)
closes poppet (5).
holding pressure of the boom cylinder bottom are
shut off.
10-71-35 PC400/450(LC)-7
(8)
3. When lowering boom
Operation
• When the boom is lowered, pilot pressure from
the PPC valve presses pilot piston (2).
• Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
• 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.
• As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
• Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
PC400/450(LC)-7 10-71-36
(8)
Arm drift preventive valve

(if equipped)
1. When arm OUT
Function
• This valve prevents the oil in the arm head from
leaking through spool (1) and the boom from low-
ering under its weight while the arm lever is not
operated.
Operation
• When the arm OUT is operated, pressurized oil
from the control valve works on the ring-shaped
area (S) [= Ø(d1) area – Ø(d2) area] caused by
the difference between the outside diameter (d1)
of poppet (5) and the seat diameter (d2) to move
it to the left.
• Contracts spring (4) and poppet (5) moves to the
left.
• As a result, pressurized oil from the control valve
passes through the opening of poppet (5) and
flows to the arm cylinder head.
10-71-37 PC400/450(LC)-7
(8)
2. When the arm is in neutral
Operation
• Moves the lever to neutral with the arm dumped.
• Pressurized oil flown inside poppet (5) from ori-
fice (a) of poppet (5) is closed by pilot piston (2).
holding pressure of the arm cylinder head are
shut off.
• The holding pressure of arm cylinder head works
on ring-shaped area (S) caused by the difference
between outside diameter (d1) of poppet (5) and
seat diameter (d2) to move it to the right.
• The sum of this force and the force of spring (4)
closes poppet (5).
holding pressure of the arm cylinder head are
shut off.
PC400/450(LC)-7 10-71-38
(8)
3. When arm IN
Operation
• If arm is set to IN, pilot piston (2) is pushed by the
pilot pressure from the PPC valve.
• Pressurized oil in chamber (b) inside the poppet
is drained through orifice (c).
• 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.
• As the pressure of chamber (b) lowers under the
pressure of port (B), poppet (5) opens.
• Pressurized oil from port (B) is led to port (A) and
then flows to the control valve.
10-71-39 PC400/450(LC)-7
(8)
4. When abnormally high pressure is generated
• If abnormally high pressure is generated in the • 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(LC)-7 10-71-40
(8)
Quick return valve

1. When arm OUT
Function
• When arm is set to out, large volume of oil re-
turns from the cylinder bottom.
• Reduces this pressure loss.
Operation
• When arm is set to out, pilot piston (1) is pushed • Or (Ød2 pressure receiving force > Ød1 pressure
by the pilot spool from the PPC valve. receiving force + spring force)
• Pressurized oil in chamber (b) inside the valve is • Valve (2) is pressed to the left and pressurized oil
drained through orifice (c). is led from port (A) to (B).
• Pressurized oil of the arm bottom side flows to • From port (B), pressurized oil is drained directly
orifice (a) o chamber (b) o orifice (c) o drain (T), to the tank.
and the pressure in chamber (b) lowers.
• If the pressure of chamber (b) drops lower than
that of port (A), pressure receiving force of the
pressure receiving portion [Ød2 area (S2) (seat
diameter area)] on the side of port (A) increases
by the sum of the pressure receiving force of
pressure receiving portion[Ød1 area (S1)] on the
chamber (b) side of valve (2) and the spring
force.
10-71-41 PC400/450(LC)-7
(8)
2. When the arm is in neutral
Operation
• Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0 kg/
cm2}.
• The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
• The holding pressure on the arm bottom side
works on the difference between areas (S2) and
(S1) of valve (2) to the right.
• 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(LC)-7 10-71-42
(8)
Lift check valve

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

PA =
Area of Ød1
10-71-43 PC400/450(LC)-7
(8)
Main relief valve
1. Spring
2. Poppet
Function
• Set pressure of the relief valve is in two stages.
• When power is needed, pilot pressure (P) is
turned ON and the set pressure becomes higher.
Operation
• The set pressure of relief valve is determined by
spring (1) installed load. (1st stage)
• Respective setting is not required for both the 1st
and 2nd stages. Setting the 1st stage completes
the setting of the 2nd stage.
1. If pilot pressure (P) is OFF: Low-pressure

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

setting
Spring (1) installed load is added with pilot pres-
sure (P) applied to the area of poppet (2) diam-
eter (d1), raising the set pressure to higher
level.
PC400/450(LC)-7 10-71-44
(8)
2-stage suction safety valve

[Installed to port (B) on the boom cylinder head side and port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function Operation
• Enables to provide the safety valve set pressure • The safety set pressure is determined by spring
in two stages, and make the low-pressure setting (1) installed load.
smaller.
• Enables to relieve a load without lever operation 1. If pilot pressure is OFF (high-pressure set-
if high load is applied to the cylinder. ting)
• Improves work efficiency and reduces machine • Since pilot pressure (P) is OFF, piston (2) is
body vibration. pressed to the left by spring (3). [Spring (1) in-
stalled load < spring (3) installed load]
• Spring (1) installed load becomes maximum and
the set pressure rises.
• Passage (B) is interconnected to the drain circuit
via passage (C) and chamber (D).
10-71-45 PC400/450(LC)-7
(8)
2. If pilot pressure is ON (low-pressure setting)

• If the pilot pressure (P) is ON, the pilot pressure
is led to section (A) via passage (B) and works on
the pressure-receiving bore section (d2 – d1).
• This pilot pressure contracts spring (3), and pis-
ton (2) moves to the right until making contact
with holder (4).
• Spring (1) stretches, installed load is reduced,
and the set pressure lowers.
• Pressurized oil proportionate to the piston stroke
is drained via passage (C) and chamber (D).
PC400/450(LC)-7 10-71-46
(8)
Variable pressure compensation valve

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

valve spool) • Regulates flow distribution to the service valve
B. Cylinder port when the service valve (attachment) and the
C. Load pressure of other work equipment work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area ratio
1. Valve variable)
2. Spring • Pressurized oil from the service valve spool is
3. Sleeve applied to the left side of valve (1) and is led to
4. Poppet chamber (g) via orifice (a).
5. Spring • LS pressure is led to chamber (e) through orifice
6. Screw (d).
7. Locknut • Pressurized oil of cylinder port is led to chamber
8. Cap (h) through passage (c) and orifice (f).
• The force of spring (2) acts on valve (1), and the
force of spring (5) acts on poppet (4).
• The force of spring (5) can be adjusted with
screw (6).
10-71-47 PC400/450(LC)-7
(8)
Operation when jointly operated with a high-load work equipment (such as the boom raising)
• Both of the pump discharge pressure (P) and LS • 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 the larger than the force of spring (5), poppet (4) is
attachment to operate. pressed to the right.
• If the difference between the pump discharge • 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 • Differential pressure is generated between the
following equation: upstream and downstream of orifice (a), which
reduces the pressure force in chamber (g).
P × A1 = P × A2 + LS(A2 – 1) + F • Force that presses valve (1) to the left is re-
duced.
A1: Area of Ød1 • A state is reached where the area ratio has be-
A2: Area of Ød2 come smaller.
F: Force of spring • Valve (1) moves to the right, and the flow in-
P: Pump discharge oil pressure creases from the pump to the cylinder.
PC400/450(LC)-7 10-71-48
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
ACC: To accumulator 1. Spool

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

Free length × Installed If damaged or
3 Spool return spring Outside diameter length deformed, replace
834 N 667 N spring.
132 × 29 114.5
{85.0 kg}
— {68.0 kg}
10-71-49 PC400/450(LC)-7
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
Function
• When a breaker is installed, the return oil from
the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
• When other attachments (crusher, etc.) are in-
stalled, the attachment and the main valve are in-
terconnected.
Operation
1. When attachment other than breaker is 2. When breaker is installed
installed • Pilot pressure (P1) from the attachment circuit
• 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.
• Ports (ATT) and (V) are interconnected and ports • Ports (ATT) and (V) are shut off and ports (ATT)
(ATT) and (T) are shut off. Attachment is thus in- and (T) are interconnected.
terconnected to the control valve. • Pressurized oil returning from the breaker re-
turns directly to the hydraulic tank via port (T)
without passing through the control valve.
PC400/450(LC)-7 10-71-50
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
HOLDING VALVE
(For the boom and arm)
10-71-51 PC400/450(LC)-7
(8)
CY: To work equipment cylinder

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

7 Check valve spring Outside diameter length
12.7 N 10.2 N
20.8 × 12.2 13.5
{1.3 kg}
— {1.04 kg} If damaged or
{6.0 kg}
78.5 N 62.8 N
{8.0 kg} — {6.4 kg}
126 N 100 N
{12.8 kg}
— {10.2 kg}
PC400/450(LC)-7 10-71-52
(8)
Function
• Prevents the pressurized oil from reversing from
the work equipment cylinder in order to prevents
sudden drift of the work equipment at breaking of
the piping between the control valve and the
work equipment cylinder.
Operation
1. When the work equipment lever is in neutral
When the piping is free of breakage If the piping is bursted

• Check valve (5) is closed under the holding pres- • If piping (A) is broken between the control valve
sure of the cylinder led from port (CY) to cham- and the work equipment cylinder, chambers (a)
ber (b). and (b) are shut off in the same way as the piping
• At the neutral, pilot pressure led to port (PI) from is free from damages.
the PPC valve is 0 MPa {0 kg/cm2}. • Pressure for the work equipment cylinder is held
• Spool (1) is pressed to the left by the force of to prevent a sudden drop of the work equipment.
springs (2) and (3)
• Chambers (a) and (b) are shut off.
• No pressurized oil flows between the control
valve and the work equipment cylinder.
• Accordingly, the work equipment is held in posi-
tion.
• If the work equipment cylinder has abnormally
high pressure, safety valve (4) is actuated by the
holding pressure of the work equipment cylinder.
• Chambers (b) of L.H. and R.H. holding valve for
the boom are interconnected by port (PCY).
• Chambers (b) will have the same pressure if the
L.H. and R.H. holding valves have a difference in
leakage.
10-71-53 PC400/450(LC)-7
(8)
2. When pressurized oil flows from the main

valve to the cylinder
When the piping is free of breakage

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

• If piping (A) between the control valve and the
work equipment cylinder is broken, pressurized
oil in chamber (a) flows outside from the dam-
aged portion.
• Pressure force in chamber (a) drops.
• Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b) and
spring (6).
• Check valve (5) closes and chambers (a) and (b)
are cut off.
• Pressure for the work equipment cylinder is held
to prevent a sudden drop of the work equipment.
PC400/450(LC)-7 10-71-54
(8)
3. When returning pressurized oil to the main

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

• Holding pressure of the work equipment cylinder • If piping (A) bursts between the control valve and
is led to chamber (b) and check valve (5) closes. the work equipment cylinder.
• Pilot pressure from the PPC valve is led to port • Pressurized oil in chamber (a) flows out to the
(PI) and reaches [Pilot Pressure > Force of bursted portion but resupplied from chamber (b).
Spring (3)] (area of d). • Since pressurized oil flows via opening (c) of
• Spool (1) moves to the right to the standby posi- spool (1), a sudden drop of the cylinder is pre-
tion. (1st stage stroke) vented.
• At this point, chambers (a) and (b) are not inter-
connected.
• Pilot pressure further rises, and reaches [Pilot
pressure > Force of spring (2)] (area of d).
• Spool (1) moves further to the right, and cham-
bers (a) and (b) are interconnected. (2nd stage
stroke)
• Pressurized oil returns to the control valve from
the work equipment cylinder.
10-71-55 PC400/450(LC)-7
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF230ABE-5
Specifications
B : From swing lock solenoid valve Model KMF230ABE-5
S : From control valve Theoretical displace-
T : To tank 229.4 cm³/rev
ment
MA : From control valve
MB : From control valve Safety valve set 27.9 +0.5
+0 MPa
pressure {285 +0.5 kg/cm2}
+0
Rated revolving
1,413 rpm
speed
Brake release
1.9 ± 0.4 MPa {19 ± 4 kg/cm2}
pressure
10-72 PC400/450(LC)-7
1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder block 17. Shuttle valve
4. Case 11. Valve plate
5. Disc 12. Reverse prevention valve
6. Plate 13. Center shaft
7. Brake piston 14. Center spring
10-74 PC400/450(LC)-7
Unit: mm

Free length Installed Installed Installed
Free length
18 Check valve spring × OD length load load If damaged or
6.96 N 5.59 N deformed,
66.5 × 25.6 45 — replace 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(LC)-7 10-75
RELIEF VALVE
1. Outline
The relief portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
2. Function
When the swing is stopped, the outlet port circuit
of the motor from the control valve is closed, but
the motor continues to rotate under inertia, so
the pressure at the output side of the motor
becomes abnormally high, and this may dam-
age the motor.
To prevent this, the abnormal high pressure oil is
relieved to port S from the outlet port of the
motor (high-pressure side) to prevent any dam-
age.
3. Operation
1) When starting swing
• When the swing control lever is operated to
swing right, the pressure oil from the pump pass-
es through the control valve and is supplied to
port MA. As a result, the pressure at port MA ris-
es, the starting torque is generated in the motor,
and the motor starts to rotate. The oil from the
outlet port of the motor passes from port MA
through the control valve and returns to the tank.
(Fig. 1)
2) When stopping swing

• When the swing control lever is returned to neu-
tral, the supply of pressure oil from the pump to
port MA is stopped. With the oil from the outlet
port of the motor, the return circuit to the tank is
closed by the control valve, so the pressure at
port MB rises. As a result, rotation resistance is
generated in the motor, so the braking effect
starts.
• If the pressure at port MB becomes higher than
the pressure at port MA, it pushes shuttle valve
A (4) and chamber C becomes the same pres-
sure as port MB. The oil pressure rises further
until it reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on the mo-
tor and stops the motor. (Fig.2)
• When relief valve (1) is being actuated, the relief
oil and oil from port S passes through check
valve B (3) and is supplied to port MA. This pre-
vents cavitation at port MA.
10-76 PC400/450(LC)-7
(1)
Operation of swing lock

1. When swing lock solenoid valve is deactivat-
ed
When the swing lock solenoid valve is deacti-
vated, the pressurized oil from the main pump is
shut off and port B is connected to the tank cir-
cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
2. When swing lock solenoid valve is activated

When the swing lock solenoid valve is activated,
the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are sepa-
rated and the brake is released.
PC400/450(LC)-7 10-77
(1)
REVERSAL PREVENTION VALVE

Outline diagram
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
Explanation of effect
10-78 PC400/450(LC)-7
Outline
This valve reduces the swing back generated in
the swing body by the inertia of the swing body,
the backlash and rigidity of the machinery sys-
tem, and the compression of the hydraulic oil
when the swing is stopped. This is effective in
preventing spillage of the load and reducing the
cycle time when stopping the swing (the posi-
tioning ability is good and it is possible to move
swiftly to the next job.
Operation
1. When brake pressure is being generated at
port MB
• Pressure MB passes through the notch and goes
to chamber d, spool (5) pushes spring (6) ac-
cording to the difference in area D1 > D2, moves
to the left, and MB is connected to e.
When this happens, pressure MA is below the
set pressure of spring (3), so spool (2) does not
move. For this reason, the pressure oil is closed
by spool (2), and the braking force is ensured.
2. After motor stops

• The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
When this happens, reversal pressure is gener-
ated at port MA. Pressure MA goes to chamber
a, so spool (2) pushes spring (3) and moves to
the right, and MA is connected to B. At the same
time, b is connected to f through the drill hole in
spool (5), so the reversal pressure at port MA is
bypassed to port T to prevent the 2nd reversal.
PC400/450(LC)-7 10-79
(1)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. Cover A1 : To L.H. travel motor port PB T2 : To tank

2. Body A2 : From control valve port A2 T1 : From L.H. and R.H. travel
3. Slipper seal C1 : To R.H. travel motor port PA motors port T
4. O-ring B2 : From control valve port B2 D2 : From control valve port B5
5. Shaft D1 : To R.H. travel motor port PB B1 : To L.H. travel motor port PA
E : To L.H. and R.H. travel C2 : From control valve port A5
motors port P
Unit: mm
Standard Size Standard clearance Repair limit If damaged or

Clearance between rotor and
6 deformed,
shaft 80 — — replace spring
10-80 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
KMV280ADT
Port T (to tank) Specifications

Port PA (from control valve)
Port PB (from control valve) Model: KMV200ADT
Port PI (from travel speed solenoid valve) Theoretical delivery Min 130 cm3/rpm
Max 200 cm3/rpm
Brake releasing pressure: 1.0 ± 0.4 MPa
{10 ± 4 kg/cm2}
Travel speed switching pressure:
0.8 +0.4
–0.1 MPa {8 –1 kg/cm }
+4 2
(Differentical pressure)
10-82 PC400/450(LC)-7
1. Output shaft 8. Regulator piston 15. Safety valve

2. Motor case 9. Plate 16. Rgegulator valve
3. Piston 10. Disc 17. Spring
4. Cylinder 11. Check valve spring 18. Brake spring
5. Valve plate 12. Check valve 19. Brake piston
6. End cover 13. Counterbalance valve 20. Check valve
7. Slow return valve 14. Spool return spring
PC400/450(LC)-7 10-83
Unit: mm

Free length Installed Installed Installed
Free length
21 Spool return spring × OD length load load
Replace
426.6N 341.3 N
62.52 × 32.0 42.0 — spring if dam-
{43.5 kg} {32.2 kg}
aged or
3.04 N 2.45 N deformed
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 kg} {8 kg}
10-84 PC400/450(LC)-7
Operation of moter
1) At low speed (motor swash plate angle at
maximumu)
• The solenoid valve is de-energized, so the pilot • As a result, valve plate (5) and cylinder block (4)
pressure oil from the main pump does not flow to move in the maximum swash plate angle direc-
port P tion, the motor capacity becomes maximum, and
For this reason, regulator valve (16) is pushed the system is set to low speed.
down by spring (17).
• The main pressure oil from the control valve push-
es check valve (20), goes to end cover (6), in reg-
ulator valve (16) and acts also on chamber b.
• When this happens, the propulsion force of reg-
ulator piston (8) acts in a downward direction.
PC400/450(LC)-7 10-85
2) At high speed (motor swash plate angle at

minimum)
• When the solenoid valve is energized, the pilot

pressure oil from the main pump flows to port P,
and pushes regulator valve (16) up.
• As a result, the oil in chamber b is drained inside
the case, and acts on chamber a via regulator
valve (16).
• Because of this, the propulsion force of the pres-
sure oil at chamber a of regulator piston (8) acts
in a upward direction.
• As a result, valve plate (5) and cylinder block (4)
move in the minimum swash plate angle direc-
tion, the motor capacity becomes minimum, and
the system is set to hign travel speed.
10-86 PC400/450(LC)-7
PARKING BRAKE
1. When starting to travel
Operation
• When the travel lever is operated, the pressu-

rized oil from the pump actuates counterbalance
valve spool (13), opens the circuit to the parking
brake, and flows into chamber e of brake piston
(19). It overcomes the force of spring (18), and
pushes piston (19) to the right.
• When this happens, the force pushing plate (9)
and disc (10) together is lost, so plate (9) and
disc (10) separate and the brake is released.
PC400/450(LC)-7 10-87
2. When stopping travel
Operation
valve (7) when the brake piston returns, and this
• When the travel lever is placed in neutral, coun- ensures that the brake is applied after the ma-
terbalance valve spool (13) returns to the neutral chine stops.
position and the circuit to the parking brake is
closed.
• The pressurized oil in chamber e of brake piston
(19) passes through the throttle of slow return
valve (7) until spool (13) of the counterbalance
valve returns to neutral.
• When spool (13) of the counterbalance valve re-
turns to the neutral position, the oil is drained in-
side the case from the throttle f of brake piston
(19) and brake piston (19) is pushed fully to the
left by spring (18).
• As a result, plate (9) and disc (10) are pushed to-
gether, and the brake is applied.
• A time delay is provided by having the pressu-
rized oil pass through a throttle in slow return
10-88 PC400/450(LC)-7
Operation of brake valve

• The brake valve consists of a check valve (1),
counterbalance valve (2), and safety valve (3) in
a circuit as shown in the diagram on the right.
• The function and operation of each component is
as given below.
1) Counterbalance valve, check valve
Function
• When traveling downhill, the weight of the ma-
chine makes it try to travel faster than the speed
of the motor.
As a result, if the machine travels with the engine
at low speed, the motor will rotate without load
and the machine will run away, which is extreme-
ly dangerous.
To prevent this, these valves act to make the ma-
chine travel according to the engine speed
(pump discharge amount).
Operation when pressurized oil is supplied

rized oil from the control valve is supplied to port
PA. It pushes open check valve (12a) and flows
from motor inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by check
valve (12b) and spool (13), so the pressure at the
supply side rises.
PC400/450(LC)-7 10-89
• The pressurized oil at the supply side flows from

orifice E1 in spool (13) and orifice E2 in the pis-
ton to chamber S1. When the pressure in cham-
ber S1 goes above the spool switching pressure,
spool (13) is pushed to the right.
As a result, port MB and port PB are connected,
the outlet port side of the motor is opened, and
the motor starts to rotate.
Operation of brake when traveling downhill

• If the machine tries to run away when traveling
downhill, the motor will turn under no load, so the
pressure at the motor inlet port will drop, and the
pressure in chamber S1 through orifices E1 and
E2 will also drop.
When the pressure in chamber S1 drops below
the spool switching pressure, spool (13) is re-
turned to the left by spring (14), and outlet port
MB is throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, the spool moves to a position
where the pressure at outlet port MB balances
the pressure at the inlet port and the force gener-
ated by the weight of the machine. It throttles the
outlet port circuit and controls the travel speed
according to the amount of oil discharged from
the pump.
2) Safety valve (2-direction operation, 2-stage

set safety valve)
Function
• When travel is stopped (or when traveling down-
hill), the circuits at the inlet and outlet ports of the
motor are closed by the counterbalance valve.
However, the motor is rotated by inertia, so the
pressure at the outlet port of the motor will be-
come abnormally high and will damage the motor
or piping.
The safety valve acts to release this abnormal
pressure and send it to the inlet port side of the
motor to prevent damage to the equipment.
10-90 PC400/450(LC)-7
(1)
Operation in both directions

1) When pressure in chamber MB has become
high (when rotating clockwise)
• When the travel is stopped (or when traveling
downhill), chamber MB in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises be-
cause of inertia.
• If the pressure goes above the set pressure, the
force produced by the difference in area between
D1 and D2 [x/4 (D12 – D2) × pressure] overcomes
the force of the spring and moves the poppet to
the left, so the oil flows to chamber MA in the cir-
cuit on the opposite side.
2) When stopping travel (low-pressure setting)

• When the travel lever is placed at neutral, the
pressure in chamber PA drops and counterbal-
ance valve spool (13) returns to the neutral posi-
tion. While the counterbalance valve spool (13) is
returning to the neutral position, the pressurized
oil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. The
piston moves to the left, and the set load be-
comes smaller.
Because of this, the set pressure of the safety
valve is switched to the low-pressure setting and
relieves the shock when reducing speed.
[Set pressure of safty valve]

When starting or traveling: When stopping:
High-pressure setting Low-pressure setting
40.2 MPa {410 kg/cm2} 27.5 MPa {27.5 kg/cm2}
PC400/450(LC)-7 10-91
3) When pressure in chamber MA has become

high (when rotating counterclockwise)
• When the travel is stopped (or when traveling
downhill), chamber MA in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises be-
cause of inertia.
• If the pressure goes above the set pressure, the

force produced by the difference in area between
D1 and D3 [x/4 (D3 2 – D1 2) × pressure] over-
comes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MB
in the circuit on the opposite side.
Operation of mechanism for varying set

pressure
1) When starting travel (high-pressure setting)
rized oil from the pump actuates counterbalance
valve spool (19), and opens the pilot circuit to the
safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes the
piston to the right, and compresses the spring to
make the set load larger. Because of this, the set
pressure of the safety valve is switched to the
high pressure setting, and a large drawbar pull is
made available.
10-92 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing “RIGHT”
2. Service PPC valve 9. Accumulator (2) Boom “RAISE” (10) Swing “LEFT”
3. Service pedal 10. Control valve (3) Boom “LOWER” (11) Neutral
4. L.H. travel lever 11. Hydraulic pump (4) Bucket “DUMP” (12) Travel “REVERSE”
5. R.H. travel lever 12. Junction box (5) Bucket “CURL” (13) Travel “FORWARD”
6. R.H. PPC valve 13. L.H. work equipment (6) Hold
7. R.H. work equipment control lever (7) Arm “IN”
control lever 14. L.H. PPC valve (8) Arm “OUT”
PC400/450(LC)-7 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE

Function
• If boom RAISE or arm IN are operated when the

machine is traveling, the stroke of the spools for
the boom and arm is controlled by the travel PPC
pressure and this limits the flow of oil to the boom
and arm cylinders.
• When the boom and arm stroke is controlled, the
travel PPC pressure passes through the circuit
inside the control valve to actuate the system.
Operation
1. When travel is at neutral

• Stroke limit signal chambers a and b are con-
nected to the travel PPC valve through orifices
(5) and (6) in pistons (3) and (4) inside the travel
spring case, and the is drained.
• When arm IN is operated, spool (1) moves to the
right by stroke (st0) to a point where it contacts
the end face of spring case (2).
• When boom RAISE is operated, spool (9) moves
to the left by stroke (st3) to a point where it con-
tacts the end face of spring case (10).
10-96 PC400/450(LC)-7
PC400/450(LC)-7 10-97
2. When travel is operated

• When the travel lever is operated to right RE-
VERSE (or FORWARD), the right (REVESE (or
FORWARD) PPC pressure pushes spool (7) to
the left (or right).
• Spool (7) pushes piston (3), orifice (5) closes,
and stroke limit signal chamber a is shut off from
the drain circuit of the travel PPC valve.
• At the same time, the right REVERSE (or FOR-
WARD) PPC pressure passes through orifice (6)
in piston (4), acts on the right end face of piston
(8), and pushes piston (8) to the left.
• If arm IN is operated, spool (1) moves to the right,
but the maximum stroke of the spool is limited by
the amount of movement st2 of piston (8) and
becomes st1.
• If boom RAISE is operated, spool (9) tries to
move to the left, but the travel PPC pressure en-
ters stroke control signal chamber b, so the spool
does not move.
10-98 PC400/450(LC)-7
PC400/450(LC)-7 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
P : From self pressure reducing valve P1 : Left PPC: Arm OUT / Right PPC: Boom LOWER
T : To tank P2 : Left PPC: Arm IN / Right PPC: Boom RAISE
P3 : Left PPC: Swing LEFT / Right PPC: Bucket CURL
P4 : Left PPC: Swing RIGHT / Right PPC: Boom LOWER
10-100 PC400/450(LC)-7
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 connection of lever)
Unit: mm

Free length Installed Installed Free Installed
Centering spring
12 × OD length load length load
(For P3 and P4)
17.1 N {1.8 13.7 N {1.4 If damaged or
42.4 × 15.5 34 —
kg} kg} deformed,
replace spring
Centering spring 29.4 N 23.5 N
13 44.4 × 15.5 34 —
(For P1 and P2) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 × 8.2 24.9 —
{1.7 kg} {1.4 kg}
PC400/450(LC)-7 10-101
Operation
1) At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1)
2) During fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the main pump
passes through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP. At
almost the same time, it is connected to drain
chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that force of metering spring (2) is balanced
with the pressure at port P1. The relationship in
the position of spool (1) and body (10) (fine con-
trol hole f is at a point midway between drain
hole D and pump pressure chamber PP) does
not change untill retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also
rises in proportion to the travel of the control
lever. In this way, the control valve spool moves
to position where the pressure in chamber A
(the same as the pressure at port P1) and the
force of the control valve spool return spring are
balanced.
10-102 PC400/450(LC)-7
3) During fine control (when control lever is

returned)
• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time, it is connected to
pump pressure chamber PP, and the pump
pressure is supplied until the pressure at port P1
recovers to a pressure that corresponds to the
lever position.
When the spool of the control valve returns, oil
in drain chamber D flows in from fine control
hole f’ in the valve on the side that is not work-
ing. The oil passes through port P2 and enters
chamber B to fill the chamber with oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1, and pushes
the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows to
drain chamber D.
PC400/450(LC)-7 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From self pressure reducing valve P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal
10-104 PC400/450(LC)-7
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
PC400/450(LC)-7 10-105
Unit: mm

1 Metering spring × OD length load length load
16.7 N 13.7 N If damaged or
26.5 × 8.15 24.7 —
{1.7 kg} {1.4 kg} deformed,
replace spring
108 N 86.3 N
2 Centering spring 48.1 × 15.5 32.5 —
{11 kg} {8.8 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 × 7.3 8.5 —
{0.9 kg} {0.72 kg}
10-106 PC400/450(LC)-7
Travel signal/Steering function
• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the
travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher
one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neu-
tral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1. While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
PC400/450(LC)-7 10-107
2. While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also
operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and
right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is kept
in neutral and the steering signal (Port P6) is not output.
10-108 PC400/450(LC)-7
3. When steered or pivot-turned

(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the dif-
ference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output
as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2.
The pressure in right spring chamber (l) is P4.
If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow
and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the
steering signal to port P6.
PC400/450(LC)-7 10-109
4. When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of
steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs the
steering signal (port P6).
10-110 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE

a Refer to the section WORK EQUIPMENT •
SWING PPC VALVE for function of this valve.
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
Unit: mm

9 Centering spring × OD length load length load If damaged or
124.5 N 100 N deformed,
33.9 × 15.3 28.4 — replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 × 8.1 22 —
{1.7 kg} {1.4 kg}
PC400/450(LC)-7 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid
valves
1. PPC lock solenoid valve T : To tank A8 : To main valve (2-stage relief

2. Travel junction solenoid valve A1 : To No. 1 pump (CO valve) valve)
3. Merge-divider solenoid valve A2 : To main valve (Travel junc- P1 : From main pump
4. Travel speed solenoid valve tion valve) ACC : To accumulator
5. Swing brake solenoid valve A3 : To main valve (Merge-divider
6. Machine push-up solenoid valve valve)
8. 2-stage relief solenoid valve A4 : To both travel motors
A5 : To swing motor
A6 : To 2-stage safety valve at
boom cylinder head
10-112 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
1. Connector
2. Moving core
3. Coil
4. Spool
5. Block
6. Spring
Operation
WHEN SOLENOID IS TURNED OFF
• Since the signal current does not flow from the

controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring (6)
against the left side.
By this operation, the pass from P to A is closed
and the hydraulic oil from the main pump does
not flow into the actuator.
At this time, the oil from the actuator is drained
through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON
• The signal current flows from the controller to so-

lenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to the
right side.
By this operation, the hydraulic oil from the main
pump flows through port P and spool (4) to port
A, then flows into the actuator.
At this time, port T is closed and the oil does not
flow into the tank.
PC400/450(LC)-7 10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC ACCUMULATOR
PPC ACCUMULATOR
1
1. Gas plug
2. Shell
3. Poppet
2 4. Holder
5. Bladder
6. Oil port
3
Specifications
Gas capacity: 300 cc (for PPC)
4
SBP00290
10-114 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER

FOR BREAKER
Specifications
1. Drain plug Rated pressure : 6.9 MPa {70 kg/cm2}
2. Element Flow : 200 l/min.
3. Case Relief valve cracking pressure:
4. Head cover 0.34 ± 0.05 MPa
5. Relief valve {3.5 ± 0.5 kg/cm2}
Filter mesh size : 6 µm
Filtering area : 4,570 cm2
PC400/450(LC)-7 10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-136 PC400/450(LC)-7
(8)
Unit: mm

Cylinder
size Shaft Hole clearance limit
Clearance –0.036 +0.261 0.083 –

Boom 110 0.412
between –0.090 +0.047 0.351 Replace
1
piston rod and bushing
–0.036 +0.263 0.084 –
bushing Arm 120 0.412
–0.090 +0.048 0.353
–0.036 +0.257 0.083 –
Bucket 100 0.447
–0.090 +0.047 0.347
–0.036 +0.169 0.136 –
Boom 110 —
Clearance –0.090 +0.100 0.259
between
–0.036 +0.169 0.136 –
2 piston rod Arm 110 —
–0.090 +0.100 0.259
support pin
and bushing –0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277 Replace pin
–0.036 +0.190 0.106 – or bushing
Clearance Boom 100 —
–0.090 +0.070 0.280
between
cylinder –0.036 +0.195 0.135 –
3 Arm 110 —
bottom sup- –0.090 +0.099 0.285
port pin and
–0.036 +0.187 0.133 –
bushing Bucket 100 —
–0.090 +0.097 0.277
PC400/450(LC)-7 10-137
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-137-1 PC400/450(LC)-7
(8)
BOTTOM DUMP CYLINDER
Unit: mm
Cylinder
size Shaft Hole clearance limit
–0.036 +0.261 0.083 –
Boom 100 0.415
–0.090 +0.047 0.351
Clearance between –0.036 +0.263 0.084 –
1 piston rod and bushing Arm 120 0.453 Replace bushing
–0.090 +0.048 0.353
–0.036 +0.222 0.083 –
Bucket 95 0.412
–0.090 +0.047 0.312
–0.036 +0.257 0.084 –
Bottom dump 90 0.447
–0.090 +0.048 0.347
–0.036 +0.457 0.136 –
Boom 110 1.0
–0.090 +0.370 0.259
–0.036 +0.457 0.406 –
Clearance between Arm 110 1.0
–0.090 +0.370 0.547
2 piston rod support pin
and bushing –0.036 +0.457 0.406 –
Bucket 100 1.0
–0.090 +0.370 0.547
–0.036 +0.457 0.406 –
Bottom dump 80 1.0
–0.090 +0.370 0.547 Replace pin or
–0.036 +0.161 0.110 – bushing
Boom 100 1.0
–0.090 +0.074 0.251
–0.036 +0.457 0.496 –
Clearance between Arm 110 1.0
–0.090 +0.370 0.547
3 cylinder bottom support
pin and bushing –0.036 +0.457 0.496 –
Bucket 80 1.0
–0.090 +0.370 0.547
–0.036 +0.457 0.406 –
Bottom dump 80 1.0
–0.090 +0.370 0.547
PC400/450(LC)-7 10-137-2
(8)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-138 PC400/450(LC)-7
(8)
Unit: mm

Clearance between size clearance limit
Shaft Hole
1 connecting pin and bushing
of revolving frame and boom –0.036 +0.173 0.137 –
120 1.0
–0.090 +0.101 0.263
Clearance between
–0.036 +0.180 0.148 –
2 connecting pin and bushing 120 1.0
–0.090 +0.112 0.270
of boom and arm
Clearance between
–0.036 +0.172 0.117 –
3 connecting pin and bushing 100 1.0
–0.090 +0.081 0.262 Replace
of arm and link
Clearance between connect-
–0.036 +0.138 0.113 –
4 ing pin and bushing of arm 100 1.0
–0.090 +0.077 0.228
and bucket
–0.036 +0.172 0.117 –
5 ing pin and bushing of link 100 1.0
–0.090 +0.081 0.262
and bucket
–0.036 +0.190 0.133 –
6 ing pin and bushing of link 100 1.0
–0.090 +0.097 0.280
and link
7 Bucket clearance (a) 0.5 – 1.0
Adjust shims
8 Bucket clearance (b) 2.0
PC400/450(LC)-7 10-139
10-139-1 PC400/450(LC)-7
(8)
Unit: mm
Tolerance Standard Clearance
Clearance between connecting pin Standard size clearance limit
Shaft Hole
1 and bushing of revolving frame
and boom –0.036 +0.351
120 0.306 – 0.344 1.0
–0.090 +0.270
Clearance between connecting pin –0.036 +0.380
2 and bushing of boom and arm 120
–0.090 +0.283
0.306 – 0.470 1.0
Clearance between connecting pin –0.036 +0.352 Replace

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

–0.036 +0.338
4 and bushing of bucket cylinder 100
–0.090 +0.284
0.320 – 0.428 1.0
and bucket
Clearance between connecting pin
–0.036 +0.344
5 and bushing of front bucket and 95
–0.090 +0.272
0.308 – 0.434 1.0
rear bucket
PC400/450(LC)-7 10-139-2
(8)
1. Dimension of arm
10-140 PC400/450(LC)-7
Unit: mm
Model
PC400-7 PC450-7
No.
1 ø110 +0.1
+0 /
–0.036
–0.090 ø110 +0.1
+0 /
–0.036
–0.090
2 ø129.3 +1.5
+0 / 126 ± 1.2 ø129.3 +1.5
+0 / 126 ± 1.2
3 ø355 +0.5 –0.3

+0 / 351 –0.8 ø355 +0.5 –0.3
+0 / 351 –0.8
4 ø120 +0.1
+0 /
–0.036
–0.090 ø120 +0.1
+0 /
–0.036
–0.090
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
15 ø100 +0.1
+0 /
–0.036
–0.090 ø100 +0.1
+0 /
–0.036
–0.090
16 ø371 +1
+0 / 370 ± 0.5 ø371 +1
+0 / 370 ± 0.5
17 ø100 +0.1
+0 /
–0.036
–0.090 ø100 +0.1
+0 /
–0.036
–0.090
Arm as –0 –0
355 –0.5 355 –0.5
individual part
18
When press-
370 370
fitting bushing
Min. 1,870 1,870

19
Max. 3,140 3,140
PC400/450(LC)-7 10-141
2. Dimension of bucket
10-142 PC400/450(LC)-7
Unit: mm
Model
PC400-7 PC450-7
No.
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’
A ø140.1 +0.1
+0 ø140.1 +0.1
+0
9 B ø130 +0.063
–0 ø130 +0.063
–0
C ø100 +0.1
+0 ø100 +0.1
+0
10 371 +1
+0
371 +1
+0
A 57 58
11
B 72 72
12 144 144
13 562.5 +0.5
–2.5
562.5 +0.5
–2.5
14 ø26 ø26
A ø165 ø165
15
B — —
16 ø230 ø230
17 146.1 135.5
18 137.6 142.0
19 R115 R115
20 R85 R85
21 410 ± 1 410 ± 1
22 64 64
PC400/450(LC)-7 10-143
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Hot water pick-up piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Hot water return piping C. Hot air/cold air
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct
10-144 PC400/450(LC)-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Operation of system
Starting engine
• When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine controller
checks the signal from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

• The fuel control dial sends signal voltages to the
engine controller according to its angle.
The engine controller sends drive signals to the
supply pump according to the signal voltages
received from the fuel control dial and controls
the fuel injection pump to control the engine
speed.
Stopping engine
• When the engine controller detects that the start-
ing switch is at the OFF position, it cuts the signal
to the supply pump drive solenoid to stop the en-
gine.
PC400/450(LC)-7 10-145
(1)
2. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed at the bottom of

the monitor panel. A potentiometer is installed
under the knob, and when the knob is turned, it
rotates the potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent
to the engine controller.
• The hatched area in the graph on the right is the
abnormality detection area and the engine speed
is set at low idling.
10-146 PC400/450(LC)-7
3. Engine controller
Input and output signals
PC400/450(LC)-7 10-147
CN1 [CN-E11] CN2 [CN-E12]

Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
CN1-1 POWER (+24V constant) CN2-1 GND
CN1-2 POWER (+24V constant) CN2-2 NC
CN1-3 Model selection 1 Input CN2-3 NC Input
CN1-4 GND CN2-4 RS232C_1RX Input
CN1-5 NC Input CN2-5 NC
CN1-6 NC Output CN2-6 NC
CN1-7 GND CN2-7 NC Input
CN1-8 GND CN2-8 NC Input
CN1-9 NC Input CN2-9 Sensor 5V power supply 2 Output
CN1-10 GND CN2-10 Fuel control dial Input
CN1-11 NC Input CN2-11 S_NET_SHIELD GND
CN1-12 NC Output CN2-12 CAN_SHIELD
CN1-13 Key switch (ACC) Input CN2-13 NC Output
CN1-14 NC Input CN2-14 RS232C_1TX Output
Engine oil pressure switch (For high CN2-15 G_SHIELD (GND)
CN1-15 Input
pressure) CN2-16 Ne_SHIELD (GND)
CN1-16 Memory clear Input CN2-17 Fuel temperature sensor Input
CN1-17 Model selection 3 Input CN2-18 NC Input
CN1-18 NC Output CN2-19 Sensor 5V power supply 1 Output
CN1-19 Key switch (ACC) Input CN2-20 Boost pressure sensor Input
CN1-20 Starting switch (C) Input Input/
CN2-21 S_NET (+)
Engine oil pressure switch (For low Output
CN1-21 Input
pressure) Input/
CN2-22 CAN0_L
CN1-22 Auto deceleration signal Input Output
CN1-23 Model selection 2 Input CN2-23 NC
CN1-24 NC Output CN2-24 FWE_switch Input
CN2-25 G pulse (–) Input
CN2-26 Ne pulse (–) Input
CN2-27 Coolant temperature sensor (High) Input
CN2-28 NC Input
CN2-29 Analog GND
CN2-30 NC Input
Input/
CN2-31 S_NET (+)
Output
Input/
CN2-32 CAN0_H
Output
CN2-33 NC
CN2-34 GND (232C_GND)
CN2-35 G pulse (+) Input
CN2-36 Ne pulse (+) Input
CN2-37 Coolant temperature sensor (Low) Input
CN2-38 NC Input
CN2-39 Analog GND
CN2-40 Common rail pressure sensor Input
10-148 PC400/450(LC)-7
(1)
CN3 [CN-E13]
Input/
Pin No. Signal name
Output
CN3-1 Power supply for power
CN3-3 NC
CN3-4 NC
CN3-5 Injector #3 (+) Output
CN3-7 NC Input
CN3-8 Output mode selection 1 (Test mode) Input
CN3-9 Lever neutral flag (Test mode) Input
CN3-10 Engine rotation pulse output Output
CN3-11 Power GND Input
CN3-12 Supply pump 1 (+) Output
CN3-13 Supply pump 2 (+) Output
CN3-15 Injector #3 (–) Output
CN3-17 NC Input
CN3-18 Output mode selection 2 (Test mode) Input
CN3-19 NC Input
CN3-20 Q command output Output
CN3-22 Supply pump 1 (–) Output
CN3-23 Supply pump 2 (–) Output
CN3-27 NC Output
CN3-28 Auto deceleration flag (Test mode) Input
CN3-29 NC Input
CN3-30 GND
CN3-31 Power GND
CN3-32 Power GND
CN3-37 NC Output
CN3-38 Auto deceleration control (Test mode) Input
CN3-39 NC Input
CN3-40 GND
PC400/450(LC)-7 10-149
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTIONS
a For the self-diagnosis function, see “TROUBLE SHOOTING”
PC400/450(LC)-7 10-151
TOTAL SYSTEM DIAGRAM
10-152 PC400/450(LC)-7
(1)
PC400/450(LC)-7 10-153
1. Engine and Pump control function
10-154 PC400/450(LC)-7
Function
• The operator can set the work mode switch on

the monitor panel to mode A, E, or B (or L) and
select proper engine torque and pump absorp-
tion torque according to the type of work.
• The engine throttle and pump controller detects
the speed of the engine governor set with the fuel
control dial and the actual engine speed and con-
trols them so that the pump will absorb all the
torque at each output point of the engine, accord-
ing to the pump absorption torque set in each
mode.
: The L mode is on the multi-monitor specification
machine only.
PC400/450(LC)-7 10-155
1) Control method in each mode

Mode A, Mode E
• Matching point in mode A: Rated speed
246.3 kW/1,850 rpm

Mode A
{331 HP/1,850 rpm}
213.3. kW/1,720 rpm
Mode E
{286 HP/1,720 rpm}
• If the pump load increases and the pressure ris-

es, the engine speed lowers.
At this time, the controller lowers the pump dis-
charge so that the engine speed will be near the
full output point. If the pressure lowers, the con-
troller increases the pump discharge so that the
engine speed will be near the full output point.
By repeating these operations, the controller
constantly uses the engine near the full output
point.
10-156 PC400/450(LC)-7
Mode B / (Mode L)
Mode Mode B Mode L

Partial output point 82% 61%
194.9 kW/1,730 rpm

Mode B
{261 HP / 1,730 rpm}
150.8 kW/1,250 rpm
Mode L
{202 HP / 1,250 rpm}
• At this time, the controller keeps the pump ab-

sorption torque along the constant horsepower
curve and lower the engine horsepower by the
composite control of the engine and pump.
By this method, the engine is used in the low
fuel consumption area.
machine only.
PC400/450(LC)-7 10-157
2) Function to control pump during travel

• When the travel is operated in A operation, or E
or B working mode, the working mode stays as it
is, and the pump absorption torque and engine
speed rise to A travel mode.
• If the machine travels in mode L, the working

mode and engine speed do not change, but the
pump absorption torque is increased.
machine only.
3) Function to control when emergency pump

drive switch is turned ON
• Even if the controller or a sensor has a trouble,
the functions of the machine can be secured with
pump absorption torque almost equivalent to
mode E by turning on emergency pump drive
switch (10).
In this case, a constant current flows from the
battery to the EPC valve for PC and the oil pres-
sure is sensed by only the EPC valve for PC.
10-158 PC400/450(LC)-7
2. Pump/Valve control function
Function
• The machine is matched to various types of work

properly with the 2-stage relief function to in-
crease the digging force, etc.
PC400/450(LC)-7 10-159
1) LS control function
• The change point (LS set differential pressure) of
the pump discharge in the LS valve is changed
by changing the output pressure from the LS-
EPC valve to the LS valve according to the oper-
ating condition of the actuator.
• By this operation, the start-up time of the pump
discharge is optimized and the composite opera-
tion and fine control performance is improved.
2) Cut-off function
• When the cut-off function is turned on, the PC-
EPC current is increased to near the maximum
value.
• By this operation, the flow rate in the relief state
is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off function
Condition
• The average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} and the
one-touch power maximizing function is not turned
on
The cut-off function does not work, however, while

the machine is travelling in mode A or the arm crane
operation width swing lock switch is turned on.
1) 2-stage relief function

• The relief pressure in the normal work is 34.8
MPa {355 kg/cm2}. If the 2-stage relief function is
turned on, however, the relief pressure rises to
about 37.2 MPa {380 kg/cm2}.
By this operation, the hydraulic force is increased
further.
• Operating condition for turning on 2-stage relief
function
Relief pres-
Condition
sure
• Condition
• During travel 34.8 MPa
• When swing lock switch is turned on {355 kg/cm2}
• When boom is lowered
• When one-touch power maximizing 37.2 MPa
function is turned on {380 kg/cm2}
• When L mode is operated

machine only.
10-160 PC400/450(LC)-7
3. One-touch power maximizing/machine

push-up function
Function
• Power can be increased for a certain time by op-

erating the left knob switch.
• When the machine push-up switch is operated,
the boom pushing force is increased.
PC400/450(LC)-7 10-161
1) One-touch power maximizing function

• When the operator needs more digging force to
dig up a large rock, etc., if the left knob switch is
pressed, the hydraulic force is increased about
7% to increase the digging force.
• If the left knob switch is turned on in working
mode “A” or “E”, each function is set automatical-
ly as shown below.
Working Software cut-off

Engine/Pump control 2-stage relief function Operation time
mode function
34.8 MPa {355 kg/cm2}
Matching at rated Automatically reset at
A, E Cancel
output point 8.5 sec
37.2 MPa {380 kg/cm2}
2) Machine push-up function

• Operate switch (1) to increase the boom pushing
force when digging ditches or holes on hard
ground.
2-stage safety valve

Switch
function
Setting of safety valve at
boom cylinder
OFF
14.7 MPa
{150 kg/cm2}
Setting of safety valve at
boom cylinder
ON
28.4 MPa
{290 kg/cm2}
10-162 PC400/450(LC)-7
4. Auto-deceleration function
Function
• If all the control levers are set in NEUTRAL while

waiting for a dump truck or work, the engine
speed is automatically lowered to the medium
level to reduce fuel consumption and noise.
• If any lever is operated, the engine speed rises
instantly to the set level.
PC400/450(LC)-7 10-163
(1)
Operation
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
• If all the control levers are set in NEUTRAL while

the engine speed is above the decelerator oper-
ation level (about 1,300 rpm) for 4 seconds, the
engine speed lowers to the second deceleration
level (about 1,300 rpm) and keeps at that level
until any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
• If any control lever is operated while the engine

speed is kept at the second deceleration level,
the engine speed rises instantly to the level set
with the fuel control dial.
10-164 PC400/450(LC)-7
5. Auto-warm-up/Overheat prevention
function
Function
• After the engine is started, if the engine coolant

temperature is low, the engine speed is automat-
ically raised to warm the engine. If the coolant
temperature rises too high during work, the pump
load is reduced to prevent overheating.
PC400/450(LC)-7 10-165
(1)
1) Auto-warm-up function
• After the engine is started, if the engine coolant
temperature is low, the engine speed is automat-
ically raised to warm the engine.
Operating condition (All) Operated

Coolant temperature: Below 30°C.
Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one) Reset

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

• If the engine coolant temperature rises too high • This function is turned on when the coolant tem-
during work, the pump load and engine speed perature rises above 95°C.
are reduced to prevent overheating.
Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below 105°C
Work mode: Any mode Fuel control dial: Return to low idle
Coolant tempera- Engine speed: Low idle position once.
ture: Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller is
Alarm buzzer: Sounds set to condition before operation of
function. (Manual reset)

Work mode: Mode A, E, OR B Coolant temperature: Below 102°C
Coolant tempera- Engine speed: Keep as is. • Under above condition, controller is
ture: Above 102°C Monitor alarm lamp: Lights up. set to condition before operation of
Lower pump discharge. function. (Automatic reset)

Work mode: Mode A
Coolant tempera- • Under above condition, controller is
Engine speed: Keep as is.
ture: Above 100°C set to condition before operation of
Lower pump discharge.
function. (Automatic reset)

Work mode: Travel
Coolant tempera- • Under above condition, controller is
Engine speed: Keep as is.
ture: Above 95°C set to condition before operation of
Lower travel speed.
function. (Automatic reset)
10-166 PC400/450(LC)-7
(1)
6. Swing control function
Function
The swing lock and swing holding brake functions

are installed.
PC400/450(LC)-7 10-167
1) Swing lock and swing holding brake func- 2) Quick hydraulic oil warm-up function when
tions swing lock switch is turned on
• The swing lock function (manual) is used to lock • If swing lock switch (4) is turned on, the pump-cut
machine from swinging at any position. The function is cancelled and the relief pressure rises
swing holding brake function (automatic) is used from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380
to prevent hydraulic drift after the machine stops kg/cm2}. If the work equipment is relieved under
swinging. this condition, the hydraulic oil temperature rises
• Swing lock switch and swing lock/holding brake quickly and the warm-up time can be shortened.
Lock Lock
Function Operation
switch lamp
If swing lever is set in
neutral, swing brake
Swing
operates in about 7 sec. If
OFF OFF holding
swing lever is operated,
brake
brake is released and
machine can swing freely.
Swing lock operates and
machine is locked from
Swing swinging. Even if swing
ON ON
lock lever is operated, swing
lock is not reset and
machine does not swing.
: Operation of swing holding brake release switch

• If the controller, etc. has a problem, the swing
holding brake does not work normally, and the
machine cannot swing, the swing lock can be re-
set with the swing holding brake release switch.
Swing hold-
ON OFF
ing brake
(When control has (When controller is
release
trouble) normal)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing Swing Swing
Swing holding
lock is lock is lock is
brake brake is
turned on canceled turned on
turned on
a Even if the swing holding brake release switch is

turned on, if the swing lock switch is turned on,
the swing brake is not released.
a If the swing lock is reset, swinging is stopped by
only the hydraulic brake of the safety valve.
Accordingly, if swinging is stopped on a slope,
the upper structure may drift hydraulically.
10-168 PC400/450(LC)-7
7. Travel control function
Function
• The pumps are controlled and the travel speed is

changed manually or automatically, to secure
proper travel performance matched to the type of
work and jobsite during travel.
PC400/450(LC)-7 10-169
1) Pump control function during travel

• If the machine travels in a work mode other than
mode A, the work mode and the engine speed
are kept as they are and the pump absorption
torque is increased.
a For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
1. Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the governor/
pump controller controls the pump capacity
and motor capacity at each gear speed as
shown at right to change the travel speed.
( Mi) Hi
Travel speed Lo
(Middle (High
switch (Low speed)
Speed) speed)
Pump capacity
90 82 100
(%)
Motor capacity Max. Max. Min.
Travel speed
3.2 4.5 5.5
(km/h)
ii) Automatic change according to engine speed

If the fuel control dial is used to set the
engine speed to less than 1,200 rpm:
• When traveling in Lo, it will not switch even
when set to Hi or Mi.
• When traveling in Hi or Mi, it will switch auto-
matically to Lo.
iii) Automatic changes according to pump dis-
charge pressure
When traveling with the travel speed switch
set to Hi or Mi, it the load increases, such as
when traveling uphill, and the travel pres-
sure goes above 3.23 MPa {330 kg/cm2} for
more than 0.5 sec, the travel motor capacity
will automatically change to low speed
(equivalent to Lo). (The travel speed switch
will stay at Hi or Mi.)
After continuing to travel in Lo, if the load
increases, such as when traveling on level
ground or traveling downhill, and the travel
pressure goes below 18.6 MPa {190 kg/cm2}
for more than 0.5 sec, the travel motor
capacity will automatically change and will
return to Hi or Mi.
: The “Mi” mode is on the multi-monitor speci-
fication machine only.
10-170 PC400/450(LC)-7
8. ATT flow control, circuit selector func-

tion (if equipment)
Function
This function is available only with the ATT specifica-

tion. The function acts as follows according to the
flow command and working mode from the monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is fully depressed.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is on
the multi-monitor specification machine only.
PC400/450(LC)-7 10-171
(1)
9. System component parts

1) Engine revolution sensor
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
Function
• The engine revolution sensor is installed to the

ring gear of the engine flywheel. It electrically cal-
culates the number of the gear teeth which pass
in front of it and transmits the result to the engine
throttle and pump controller.
• A magnet is used to sense the gear teeth. Each
time a gear tooth passes in front of the magnet,
a current is generated.
10-172 PC400/450(LC)-7
2) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts

Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm2}
Resetting (OFF) Pressure: 0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm2}
Function
• The junction block has 7 pressure switches, which

check the operating condition of each actuator by
the PPC pressure and transmit it to the engine
throttle and pump controller.
PC400/450(LC)-7 10-173
3) Pump pressure sensor
1. Sensor
2. Connector
Function
• The pump pressure sensor is installed to the inlet

circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits
it to the engine throttle and pump controller.
Operation
• The oil pressure applied from the pressure intake

part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the
amplifier (voltage amplifier).
• The amplifier, amplifies the received voltage and
transmits it to the engine throttle and pump con-
troller.
• Relationship between pressure P (MPa {kg/cm2})
and output voltage (V) is as follows.
V = 0.08 [0.008] × P + 0.5
10-174 PC400/450(LC)-7
(1)
Pump controller
PC400/450(LC)-7 10-175
CN-1 CN-2
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
1 NC 1 NC
2 R pump pressure sensor Input 2 Swing emergency switch Input
3 NC 3 NC Input
4 NC 4 232C_RxD Input
5 NC 5 NC
6 NC Input 6 NC
7 NC 7 Model selection 4 Input
8 F boom pressure sensor Input 8 Attachment circuit selector signal Output
9 NC 9 NC
10 Signal GND 10 NC
11 Knob SW Input 11 NC
12 NC 12 CAN shield
13 Buchet CURL PPC pressure sensor Input 13 Model selection 5 Input
14 NC 14 232C_TxD Output
15 NC Input 15 NC
16 NC 16 Travel steering signal pressure SW Input
17 Starting switch (Terminal C) Input 17 Model selection 3 Input
18 NC 18 NC
19 Arm IN PPC pressure sensor Input 19 Auto deceleration signal Output
20 NC 20 NC
21 NC Input/
21 S_NET
22 POT_PWR Output output
23 Starting switch (terminal ACC) Input Input/
22 CAN0_L
output
24 NC
23 NC
24 FWE_SW Input
25 NC
26 NC
27 Model selection 2 Input
28 NC
29 GND (pulse GND)
30 NC
31 GND (S_NET GND)
Input/
32 CAN0_H
output
33 NC
34 GND (232C GND)
35 Service valve pressure switch Input

36 NC
37 Model selection switch 1 Input
38 Swing lock switch Input
39 GND (pulse GND)
40 Engine speed sensor Input
10-176 PC400/450(LC)-7
(1)
CN-3
Input/
Pin No. Signal name
Output
1 VB (controller power) Input
2 VIS (solenoid power) Input
3 SOL_COM (solenoid common gnd)
4 Battery relay drive Output
5 NC
6 LS-EPC Output
7 Travel junction SOL Output
8 NC
9 NC Input
10 Boom RAISE pressure SW Input
11 VB (controller power) Input
12 VIS (solenoid power) Input
13 SOL_COM (solenoid common gnd) Input
14 KEY_SIG Input
15 NC
16 PC-EPC Output
17 Pump merge/divider solenoid Output
18 Heater relay drive Output
19 Bucket DUMP pressure switch Input
20 Boom LOWER pressure switch Input
21 GND (controller GND) Input
22 NC
23 SOL_COM (solenoid common gnd) Input
24 KEY_SIG Input
25 NC
26 Service flow adjustment EPC (1) Output
27 Travel Hi/Lo selector solenoid Output
28 2-stage relief solenoid Output
29 Swing pressure switch Input
30 Arm IN pressure switch
31 NC Input
34 NC
35 NC
36 NC
37 Swing parking brake solenoid Output
38 NC
39 Travel pressure switch Input
40 Arm OUT pressure switch Input
PC400/450(LC)-7 10-177
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the ma-
of the machine. It processes and immediately chine control system.
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
10-178 PC400/450(LC)-7
1. Monitor panel
Outline
• The monitor panel has the functions to display

various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
PC400/450(LC)-7 10-179

CN-1 CN3
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Key ON Input 1 NC Input
2 Key ON Input 2 NC Input
3 Washer motor output Output 3 NC Input
4 Starting signal Input 4 NC Input
5 Limit switch (W) Input 5 NC Input
6 GND 6 NC Input
7 GND 7 RS230C CTS Input
8 VB + Input 8 RS230C RXD Input
9 Wiper motor (+) Output Input/
9 RS230C RXD
10 Wiper motor (-) Output Output
11 Buzzer ON signal Input Input/
10 RS230C RXD
12 Limit switch (P) Input Output
11 BOOTSW Input
12 NC Input
CN-2 13 GND
Pin Input/
Signal name 14 CAN (SHIELD) Input
No. output
1 Engine coolant temperature Input 15 CAN (+) Input
2 Fuel level Input 16 CAN (-) Input
3 Radiator coolant level Input
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC Input
7 Engine oil pressure Input
8 Engine oil level Input
Input/
9 N/W signal
Output
Input/
10 N/W signal
Output
11 Battery charge Input
12 Hydraulic oil temperature (analog) Input
13 GND (for analog signal)
14 Personal code relay Output
15 Limit SW (window) Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND
10-180 PC400/450(LC)-7
(8)
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Engine oil pressure caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Radiator coolant level caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
PC400/450(LC)-7 10-181
(8)
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Swing holding brake

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

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

Lights up but goes out after
Power Max Being pressed
approx. 9 sec when kept pressed
Not being pressed Flashes
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
10-182 PC400/450(LC)-7
(1)
Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red
A2 102 Red
Engine coolant A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera- B3 100 Green

ture (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 467 Green
C2 381 Green
C3 295 Green
Fuel level (l)
C4 147.5 Green
C5 114 Green
C6 80.5 Red
PC400/450(LC)-7 10-183
(8)
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil
temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-
played.
Check before starting When engine is When engine is

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

Maintenance only 30 sec. after key is turned ON, then goes
out.
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
Condition of hydraulic oil Color of symbol

Low temperature (below B6 or equivalent) Black on white background
Normal (B6 – B2) No display
High temperature (above B2) White on red background
10-184 PC400/450(LC)-7
(8)
Display category Symbol Display item Display range Display method
INT ON OFF
Wiper Displays set condition
Working mode Displays set mode
Monitor
Travel speed Displays set speed
Auto-decelera- Displays actuation

ON OFF
tion status
Service meter Lights up when service

Service meter When service meter is working
indicator meter is working
PC400/450(LC)-7 10-185
(8)
SWITCHES
1. Selector switch
2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
10-186 PC400/450(LC)-7
• Working mode selector switch

The condition of the machine changes accord-
Switch that is Working mode status
ing to the switch that is pressed (A, E, L, B). It is Display
pressed after setting
possible to check the condition on the working
mode monitor display. The relationship between [A] A A mode (default)
each working mode and the monitor display is [E] E E mode
shown in the table on the right.
[L] L Heavy-lift mode
• Selector switch [B] B Swing priority mode
This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)
• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to Display Setting
switch the working mode, it is automatically set
to ON. Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
• Travel speed selector switch
Each time the travel speed selector switch is Crawler symbol + Hi High speed
pressed, the travel speed changes.
Lo o Hi o Lo ……
Use the travel speed monitor display to check Wiper actuation
the present condition. Display Setting
status
The relationship between the set speed and the
Stowing stopped or
monitor display in the table on the right. None OFF
now stowing
• Wiper switch Wiper symbol + INT INT Intermittent actuation

Each time the wiper switch is pressed, the wiper Wiper symbol + ON ON Continuous actuation
setting changes OFF o INT o ON o OFF o
……
Use the wiper monitor display to check the
present condition.
The relationship between the wiper setting and
the monitor display is as shown in the table on
the right.
PC400/450(LC)-7 10-187
• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)
• Display brightness, contrast adjustment switch

Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
10-188 PC400/450(LC)-7
SELECT MODE FUNCTION
• This is used when setting the flow in each work-

ing mode. It is possible to make the setting when
genuine attachment piping is installed and the in-
itial value setting function on the service menu
has been used to set to ATTACHMENT IN-
STALLED.
• It is possible to check on the working mode mon-
itor if this function can be set.
Working mode Monitor display

A mode [A] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
MEHOD OF USE
a Carry out the setting on the normal screen

1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
Control switch Actuation
Flow level bar graph

extends to the right

retracts to the left
3) After completing the level selection, press

input confirmation switch (3).
The selection flow level is confirmed and the
screen moves to the normal screen.
From the moment that the flow level is
selected, the content of the selection is
reflected for the attachment flow.
a Before the input confirmation switch is Flow level Flow (L/min.) Remarks
pressed, the flow level is not confirmed, 8 530 Default
so press return switch (4) to return to the
7 430
normal screen. This function can be
used to return to the previously set flow. 6 370
The relationship between the set flow 5 300
level and the flow value is as shown in
the table on the right. 4 230
3 165
2 100
1 30
PC400/450(LC)-7 10-189
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-stage
flow level.
2) Press control switch (2), or input [01] – [03]
with the numeral 10-key pad to choose one
on the three flow levels.
No. 10-key pad operation
01
02
03

input confirmation switch (3).
The selected flow level is selected.
a Before the input confirmation switch is
pressed, the flow level is not confirmed,
so press return switch (4) to return to the No. Flow level (L/min.) Remarks
operator screen. This function can be 01 230 Default
used to return to the previously set flow.
02 190
4) After the flow level is confirmed, the screen
changes to the screen shown in the diagram 03 150
on the right.
With this screen, it is possible to make fine
adjustment to the flow.
5) Press control switch (2) and select the flow
level.


10-190 PC400/450(LC)-7

input confirmation switch (3). When When When
The selected flow level is confirmed and the Flow flow is flow is flow is
Remarks
screen moves to the operator screen. level 140 l/ 220 l/ 300 l/
From the moment that the flow level is min. min. min.
selected, the content of the selection is 7 200 280 360
reflected for the attachment flow.
a Before the input confirmation switch is 6 180 260 340
pressed, the flow level is not confirmed, 5 160 240 320
se press return switch (4) to return to the
4 140 220 300 Default
normal screen. This function can be
used to return to the previously set flow. 3 120 200 280
The relationship between the set flow 2 100 180 260
level and the flow value is as shown in
the table on the right. 1 80 160 240
7) Check the set value with the working mode
monitor.
The relationship between the display level Display level Set value (l/min.)
and the set value is as shown in the table on
the right, and it is possible to check the level 8 220 or 360
of the flow that can be set. 7 200 or 340
6 180 or 320
5 160 or 300
4 140 or 280
3 120 or 260
2 100 or 240
1 80
PC400/450(LC)-7 10-191
MAINTENANCE FUNCTION
When the maintenance time for replacement,

inspection, or filling has approached for the 10 main-
tenance items, press maintenance switch (1) and
the caution display (yellow or red) appears on the
monitor display for 30 seconds after the starting
switch is turned ON to remind the operator to per-
form lubrication maintenance.
a Maintenance items
Replacement interval
No. Item
(hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor 1000
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
a The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (wiper
with less than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
10-192 PC400/450(LC)-7
(1)
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
a Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to the
maintenance list display screen.
a The maintenance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 – 10) of the mainte-
nance item to select the item.
a The cursor moves and the item is highlight-
ed.
a The display method is the same as de-
scribed on the previous page (relationship
between remaining time and caution dis-
play). If the remaining time is less than 30
hours, the item is displayed in yellow, and if
it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
1. After completing the selection, press input con-

firmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
a The check screen shows the symbol for the
maintenance item and the set time in large
letters.
a The background color of the symbol for the
item where the maintenance item was reset
is the same as the background of the screen,
so it is possible to check that it has been re-
set.
PC400/450(LC)-7 10-193
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness and

contrast of the display.
ADJUSTMENT METHOD
a Operate as follows when on the operator

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
a Relationship between menu symbol and con-
tent.
No. Symbol Content

01 Return mark Return
02 Contrast
03 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 – 02) to select either
contrast or brightness.
After completing the selection, press input con-
firmation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.


10-194 PC400/450(LC)-7
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF position,

keep return switch (1) and control switch (2) of
the monitor pressed at the same time, and the
service meter is shown on the display.
• This display is shown only while the two switches
are being pressed. When the switches are re-
leased, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter dis-
play to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the normal

screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
• If any part of the display is black, the LCD is bro-
ken.
PC400/450(LC)-7 10-195
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the machine,

the user code is displayed on the monitor to ad-
vise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-
played on the portion for the hydraulic oil temper-
ature gauge.
• If more than one user code is generated at the

same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.
10-196 PC400/450(LC)-7
• While the user code is being displayed, if the in-

put confirmation switch is pressed, the service
code and failure code can be displayed.
• If there is more than one service code or failure

code, the display switches every 2 seconds and
displays all the service codes/failure codes that
caused the user code to be displayed.
Even i f service codes/f ailure codes have
occurred, if they did not cause the user code to
be displayed, this function does not display
them.
• If the telephone number has been set using the

telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and tele-
phone number.
For details of inputting and setting the telephone
number, see SPECIAL FUNCTIONS OF MONI-
TOR PANEL in the TESTING AND ADJUSTING
section.
PC400/450(LC)-7 10-197
(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the ma-
of the machine. It processes and immediately chine control system.
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
10-197-1 PC400/450(LC)-7
(4)
1. Monitor panel
OUTLINE INPUT AND OUTPUT SIGNALS

• The monitor panel has the functions to display
CN-P01 CN-P02
various items and the functions to select modes
Pin Pin
and electric parts. No.
Signal name
No.
Signal name
The monitor panel has a CPU (Central Process-
1 Key switch (Battery) 1 Engine water temperature
ing Unit) in it to process, display, and output the
2 Key switch (Battery) 2 Fuel
information.
3 Washer motor output 3 Radiator water level
The monitor display unit consists of LCD (Liquid
Crystal Display) and LED (Light Emitting Diode). 4 Key switch (Terminal C) 4 NC
The switches are flat sheet switches. 5 Wiper contact W 5 Air cleaner clogging sensor
6 GND 6 NC
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (–) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
13 GND (For analog signal)
14 NC
15 Wind limit switch
16 Buzzer cancel
17 Swing lock
18 Preheating
19 Limit switch
20 Network (GND)
PC400/450(LC)-7 10-197-2
(4)
Display section of monitor
1. Service meter display

2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user code
are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp
11. Battery charge caution lamp
12. Air cleaner clogging caution lamp
13. Engine oil pressure caution lamp
10-197-3 PC400/450(LC)-7
(4)
Monitored items and display
When engine is
Symbol Displayed item Display range While engine is running
stopped
Max. 1,500 rpm

Max. 0.05 MPa
Lights when normal.
{0.5 kg/cm²} Flashes and buzzer
Engine oil pressure (Goes off when
Min. 1,500 rpm sounds when abnormal.
engine is started.)
Max. 0.15 MPa
{1.5 kg/cm²}
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
Lights when normal.

When charge is
Charge level (Goes off when Flashes when abnormal.
abnormal
engine is started.)
Flashes when
Engine oil level Below low level Goes off.
abnormal.
When swing is Lights up when swing is locked. Flashes when

Packing (Swing lock)
locked swing holding brake release switch is turned on.
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Lights up for 30 sec. when starting switch is set to

Preheating When preheated HEAT. Then, flashes for 10 sec. to indicated
completion of preheating.
Flashes at 102°C or higher. Flashes and

Coolant temperature
buzzer sounds at 105°C or higher.
Fuel level Flashes when below low level.
PC400/450(LC)-7 10-197-4
(4)
Oil maintenance function
1. Function and operation

At a set time after the engine oil is replaced, the oil
maintenance function is turned on to notify the oper-
ator by the LED lamp on the monitor panel that it is
time to replace the oil. The function to indicate the
phone number of the place to make contact for ser-
vice on the LCD unit is installed, too.
1) Check of elapsed time

Nothing is displayed normally until point B
shown in the figure at right after this function
is reset. If the key is turned on with the
buzzer cancel switch processed (for 2.5
seconds), however, the elapsed time is dis-
played on the service meter section.
2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval

1) The time interval is set in the interval setting
mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in the
interval setting mode, the clock display sec-
tion changes to "—" o "125" o "250" o
"500" o "d" in order. ("—" corresponds to
"Not set" and "d" corresponds to "Demo-
mode".)
4) To save the time interval, set a desired time
(mode) on the monitor panel and press and
hold the clock switch for 2.5 seconds.
10-197-5 PC400/450(LC)-7
(4)
3. Timing and contents of display

1) When replacement of oil is displayed
2) The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for
20 seconds after all segments are turned
on.
3) When elapsed time is checked
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
4. Resetting elapsed time

1) When the replacement of oil and elapsed
time are displayed, press the buzzer cancel
switch 10 seconds after all segments are
turned on (while the elapsed time is dis-
p l aye d) and h ol d f or 3 se con ds. Th e
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
5. Demo-mode
1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and replace-
ment of oil is displayed when the key is
turned on. The elapsed time does not
increase, however. The time can be reset in
this mode. Turn on the key 3 times in this
mode, and the time interval is automatically
set to "Not set" at the 4th time and after. The
elapsed time is set to "0h" and counting of
elapsed time is started.
PC400/450(LC)-7 10-197-6
(4)
Mode selector switches

1. Travel speed switch
2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
(Including setting switch)
• There are 4 sets of the mode selector switches Operations table of switch section
on the switch section. Each time one switch is a The bold letters are the positions of the switches
pressed, the machine condition changes. The reset when the starting switch is turned on.
current condition is indicated by the lighting of
Item Operation
the LED above the switch.
Work mode A↔E↔B
• The initial setting of only the work mode after the Auto-deceleration ON ↔ OFF
starting switch is turned on can be changed.
a For how to change the setting, see "Work mode Wiper OFF ↔ Intermittent ↔ ON
default setting mode" in TROUBLESHOOTING- Travel speed Hi ↔ Lo
Display and special functions of monitor panel.
10-197-7 PC400/450(LC)-7
(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of contact
type is always connected to the chassis ground.
Name of sensor Type of sensor When normal When abnormal

Engine oil level Contact ON (closed) OFF (open)
Engine oil pressure Contact OFF (open) ON (closed)
Hydraulic oil temperature Resistance — —
Coolant temperature Resistance — —
Fuel level Resistance — —
Air cleaner clogging Contact type ON (closed) OFF (open)
10-198 PC400/450(LC)-7
(8)
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Coolant temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC400/450(LC)-7 10-199
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
10-200 PC400/450(LC)-7
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2

STANDARD VALUE TABLE FOR CHASSIS (BACKHOE SPECIFICATION) ................................................. 20-3
STANDARD VALUE TABLE FOR CHASSIS (LOADING SHOVEL SPECIFICATION) ................................. 20-12
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the lock
k When carrying out work together with other workers, always use signals and do not let unauthorized people
bar, and use blocks to prevent the machine from moving.
k When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed
near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
when the coolant is still hot, the coolant will spurt out and cause burns.
PC400/450(LC)-7 20-1
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

PC400, 400LC-7
Machine model
PC450, 450LC-7
Engine SAA6D125E-3
Item Measurement condition Unit Standard value Permissible value

High idle 1,930 ± 50 1,930 ± 50
Engine speed Low idle rpm 1,000 ± 25 1,000 ± 25
Rated speed 1,850 1,850

kPa
Intake air pressure At rated output Min 107 {Min. 800} 87 {650}
{mmHg}
Exhaust gas All speed range
°C Max. 700 Max. 700
pressure (intake air temp: 20°C)
At sudden acceleration Max. 4.0 6.0
Bosch
Exhaust gas color
index
At high idle Max. 1.0 2.0
Intake valve 0.33 —
Valve clearance
mm
(normal temperature)
Exhaust valve 0.71 —
Compression Oil temperature: 40 – 60°C MPa {kg/cm2} Min. 2.9 {Min. 30} 2.0 {20}
pressure (Engine speed) (rpm) (150 – 200) (150 – 200)
(Coolant temperature:
kPa
Blow-by pressure within operating range) Max. 1.18 {Max. 120} 1.96 {200}
{mmH2O}
At rated output
(Coolant temperature:
within operating range)
At high idle (SAE30) 0.39 – 0.69 {4.0 – 7.0} 0.21 {2.1}

MPa
Oil pressure
At high idle (SAE10W) {kg/cm2} 0.34 – 0.64 {3.5 – 6.5} 0.18 {1.8}
At low idle (SAE30) Min. 0.15 {Min. 1.5} 0.08 {0.8}
At low idle (SAE10W) Min. 0.1 {Min. 1.0} 0.07 {0.7}

Oil temperature All speed range (inside oil pan) °C 90 – 120 120
Fan, alternator belt Deflection when pressed with fin-
mm Approx. 13 Approx. 13
tension ger force of approx. 58.8 N {6 kg}
Air conditioner
Deflection when pressed with fin-
compressor belt mm 14 – 16 14 – 16
ger force of approx. 58.8 N {6 kg}
tension
20-2 PC400/450(LC)-7
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

(BACKHOE SPECIFICATION)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature:
2 pumps at relief 1,930 ± 100 1,930 ± 100
• Engine at high idle
• Arm in relief condition
Engine speed

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

Bucket control valve mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve
Travel control valve
Boom control lever 85 ± 10 85 ± 10
Travel of control levers
Arm control lever • Engine stopped 85 ± 10 85 ± 10

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

Arm control lever
• Hydraulic oil temperature: {1.6 ± 0.4} {Max. 2.5}
Within operation range 12.7 ± 2.9 Max. 21.6
Bucket control lever • Engine at high idle {1.3 ± 0.3} {Max. 2.2}
• Hydraulic oil temperature: N {kg}
Within operating range 12.7 ± 2.9 Max. 21.6
Swing control lever
• At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end 24.5 ± 5.9 Max. 39.2
Lever
Travel {2.5 ± 0.6} {Max. 4.0}
control 74.5 ± 18.6 Max. 107.6
Pedal
{7.6 ± 1.9} {Max. 11}
PC400/450(LC)-7 20-3
(9)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
gory
Within operation range
• Engine at high idle 4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Working mode: A mode
• Hydraulic pump output pressure {42 ± 10} {42 ± 10}
with all control levers in NEU-
TRAL position
34.81 +1.47
–0.98 33.34 – 36.77
RAISE (37.27 +1.47
–0.98 ) (35.79 – 39.23)
{355 +15
–10 (380 +15
–10 )} {340 – 375 (365 – 400)}
At low- 18.14 ± 0.98 16.67 – 19.61

Boom • Hydraulic oil pressure
LOWER
temperature: setting {185 ± 10} {170 – 200}

Within opera-
tion range At high- 31.38 ± 1.47 29.2 – 33.34
• Engine at high pressure
setting {320 ± 15} {300 – 340}
idle
• Working mode: A mode 34.81 +1.47
–0.98 33.34 – 36.77
Arm • Hydraulic pump output pressure (37.27 +1.47
–0.98 ) (35.79 – 39.23)
with all measurement circuits
{355 –10 (380 +15
+15
–10 )} {340 – 375 (365 – 400)}
Hydraulic pressure
relieved
• Values inside parenthesis: +1.47
34.81 –0.98 33.34 – 36.77
Hydraulic oil pressure with one- MPa
Bucket touch power max. switch in ON (37.27 +1.47
–0.98 ) (35.79 – 39.23)
{kg/cm2}
mode (reference only) {355 +15
–10 (380 +15
–10 )} {340 – 375 (365 – 400)}
30.89 +1.47
–2.45 27.95 – 32.85
Swing
{315 +15
–25 } {285 – 335}
37.27 +2.94
–0.98 35.79 – 40.70
Travel
{380 +30
–10 } {365 – 415}
Control circuit source • Engine at high idle 3.24 ± 0.2 2.84 – 3.43
pressure • Self pressure reducing valve {33 ± 2} {29 – 35}
output pressure with all control
levers in NEUTRAL position
• Hydraulic oil tem- When all

perature: Within control
4.2 ± 1.0 4.2 ± 1.0
operation range levers in
{42 ± 10} {42 ± 10}
• Engine at high idle NEUTRAL
• Working mode: A position
LS differential pressure
mode When trav-
• Traveling speed: Hi eling at half
• Hydraulic oil pump 2.65 ± 0.1 2.65 ± 0.1
stroke
pressure – LS {27 ± 1} {27 ± 1}
(without
pressure load)
20-4 PC400/450(LC)-7
(9)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
gory
• Hydraulic oil temperature: deg. PC400: Max. 120 PC400: Max. 150
Swing brake angle
Within operating range (mm) PC450: Max. 130 PC450: Max. 160
• Bucket: Empty
• Engine at high idling
• Working mode: A mode
• Swing circle misalignment amount
when stopping after one turn
90° 3.7 ± 0.4 Max. 4.6

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

Hydraulic drift of swing operation range mm 0 0
• Engine stopped
• Keeping upper structure trans-
verse on slope of 15 degrees
• Notching a mating mark on inner
and outer races of swing circle
• Mating mark misalignment
amount during 5 minutes
PC400/450(LC)-7 20-5
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
gory
operation range
Swing
Leakage from swing • Engine at high idling

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

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

operation range
• Engine at idling
Travel deviation mm Max. 200 Max. 300
• Travel speed: Lo
• Solid and flat ground
• Swerving amount while traveling
20 m (X) after initial 10 m trial run.
20-6 PC400/450(LC)-7
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
gory
Hydraulic drift of travel • Hydraulic oil temperature: mm 0 0

• Engine stopped
• Parking machine on slope 12
Travel
degrees with sprocket facing ups-

lope
• Sliding distance for 5 minutes
Leakage of travel
• Travel: Lock sprocket. l/min Max. 20 Max. 40
motor
• Oil leakage amount for one
minute with traveling in relief con-
dition
Whole work
PC400: Max. 600 PC400: Max. 900
equipment (tooth
PC450: Max. 700 PC450: Max. 1,050
tip fall amount)
Hydraulic drift of work equipment
Boom cylinder
PC400: Max. 25 PC400: Max. 38
(cylinder retrac-
• Hydraulic oil temperature: Within PC450: Max. 29 PC450: Max. 44
Work equipment
tion amount)
operation range
• Flat and level ground
Arm cylinder (cyl- • Work equipment in measure- mm
PC400: Max. 85 PC400: Max. 128
inder extension ment posture as illustrated PC450: Max. 100 PC450: Max. 150
amount) above
• Bucket load: 3,060 kg
• Engine stopped
• Work equipment control lever in
Bucket cylinder
NEUTRAL position PC400: Max. 30 PC400: Max. 45
(cylinder retrac-
• Fall amount for 15 minutes as PC450: Max. 35 PC450: Max. 53
tion amount)
measured every 5 minutes start-
ing immediately after initial setting
PC400/450(LC)-7 20-7
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
RAISE
PC400: 4.0 ± 0.4 PC400: Max. 4.8
PC450: 4.2 ± 0.4 PC450: Max. 5.0
Boom • Hydraulic oil temperature:

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

Work equipment
Arm • Hydraulic oil temperature: sec.

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

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

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

• Time required from dump-
ing stroke end to digging
stroke end
20-8 PC400/450(LC)-7
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Boom sec. Max. 3.0 Max. 3.6

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

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

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

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

Cylinders 4.5 20
cc/min
• Leakage amount for one
Center swivel minute with cylinder or travel to
10 50
joint be measured in relief condition
PC400/450(LC)-7 20-9
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

Performance in compound operation

• Traveling speed: Lo
• Flat and level ground
Swerving amount in • Swerving amount (X) when
simultaneous opera- traveling 20 m after initial trial
run of 10 m mm Max. 400 Max. 440
tion of work equip-
ment and travel
hydraulic pump
Performance of
Hydraulic pump
See next page l/min See next page
delivery
20-10 PC400/450(LC)-7
(1)
PC400, 400LC-7
Applicable model
PC450, 450LC-7
Cate- Permissible
Item Measurement Condition Unit Standard value
gory value
Discharge amount of hydraulic pump (A mode)

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

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

2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
PC400/450(LC)-7 20-11
(1)
STANDARD VALUE TABLE FOR CHASSIS

(LOADING SHOVEL SPECIFICATION)
Applicable model PC400LC-7
Cate-
gory
2 pumps at relief 1,930 ± 100 1,930 ± 100
• Arm in relief condition
Engine speed

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

Bucket control valve mm 9.5 ± 9.5 ± 9.5 ± 9.5 ±
— —
Swing control valve 0.5 0.5 0.5 0.5
Travel control valve BLP00101
Max. 95
Boom control lever 85 ± 10
Min. 75
Max. 95
Arm control lever 85 ± 10
Travel of control levers
Min. 75
• Engine stopped Max. 95
Bucket control lever 85 ± 10
• At center of control lever grip Min. 75
• Max. reading up to stroke end mm
(excepting lever play in NEU- Max. 95
Swing control lever 85 ± 10
TRAL position) Min. 75
Max. 127
Travel control lever 115 ± 12
Min. 103
Work equipment,
Play of control levers Max. 10 Max. 15
swing
15.68 ± 3.92 Max. 24.5

Boom control lever
{1.6 ± 0.4} {Max. 2.5}
Operating effort of control levers
15.68 ± 3.92 Max. 24.5

Arm control lever
{1.6 ± 0.4} {Max. 2.5}
Within operation range 12.74 ± 2.94 Max. 21.56
Bucket control lever • Engine at high idle {1.3 ± 0.3} {Max. 2.2}
• Hydraulic oil temperature: N {kg}
Within operating range 12.74 ± 2.94 Max. 21.56
Swing control lever
• At center of control lever grip {1.3 ± 0.3} {Max. 2.2}
• Max. reading up to stroke end
24.5 ± 5.88 Max. 39.2
Lever
Travel {2.5 ± 0.6} {Max. 4.0}
control 74.48 ± 18.62 Max. 107.8
Pedal
{7.6 ± 1.9} {Max. 11}
20-12 PC400/450(LC)-7
(9)
Cate-
gory
operation range
4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Working mode: A mode
• Hydraulic pump output pressure {42 ± 10} {42 ± 10}
with all control levers in NEU-
TRAL position
33.83 – 36.28 33.34 – 36.77
RAISE
{345 – 370} {340 – 375}
At low- 30.9 – 33.8 33.38 – 34.3
Boom pressure
LOWER
setting {315 – 345} {310 – 350}
At high- 17.1 – 20.5 16.66 – 21.07
pressure
setting {175 – 210} {170 – 215}
31.8 – 34.3 31.36 – 34.79

• Oil temperature: IN
{325 – 350} {320 – 355}
Arm 45 – 55°C
• Engine at full 31.8 – 34.3 31.36 – 34.79
OUT
throttle {325 – 350} {320 – 355}
• In heavy duty
mode 32.3 – 34.79 31.85 – 35.28
CURL
• Pump outlet port {330 – 355} {325 – 355}
Bucket
Hydraulic pressure
pressure 31.8 – 34.3 31.36 – 34.79

• Relive only cir- DUMP
{325 – 350} {320 – 355}
cuit being mea- MPa
sured {kg/cm2} 31.8 – 34.3 31.36 – 34.79
OPEN
{325 – 350} {320 – 355}
Bottom dump
29.9 – 33.3 29.4 – 33.81
CLOSE
{305 – 340} {300 – 345}
30.89 +1.47
–2.45 27.95 – 32.85
Swing
{315 +15
–25 } {285 – 335}
37.27 +2.94
–0.98 35.79 – 40.70
Travel
{380 +30
–10 } {365 – 415}
Control circuit source • Engine at high idle 3.24 ± 0.2 2.84 – 3.43
pressure • Self pressure reducing valve {33 ± 2} {29 – 35}
output pressure with all control
levers in NEUTRAL position
• Hydraulic oil temper- When all
ature: Within opera- control 4.2 ± 1.0 4.2 ± 1.0
tion range levers in
NEUTRAL {42 ± 10} {42 ± 10}
• Working mode: A position
LS differential pressure
mode When trav-
• Traveling speed: Hi eling at half
• Hydraulic oil pump 2.65 ± 0.1 2.65 ± 0.1
stroke
pressure – (without {27 ± 1} {27 ± 1}
LS pressure load)
PC400/450(LC)-7 20-13
(9)
Cate-
gory
Work equipment posture: Max. reach
Overrun when stopping

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

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

45 – 55°C
• In H/O mode
• Swing one turn, then measure
time taken to swing next 5 turns
• Engine stopped
Hydraulic drift of swing • Hydraulic oil temperature: mm 0 0
45 – 55°C
• Set machine on 15° slope, and
set upper structure at 90° to the
side
• Make match marks on swing cir-
cle outer race and track frame
• Measure distance that match
marks move apart after 5 minutes
20-14 PC400/450(LC)-7
(9)
Cate-
gory
Swing
Leakage from swing

45 – 55°C l/min Max. 5.5 Max. 11
motor
• Swing lock switch ON
• Relieve swing circuit
Lo 67.3 ± 13.5 45.0 – 84.5
Travel speed Mi 48.1 ± 7.2 34.0 – 58.0

• Hydraulic oil temperature: sec.
(Idle travel)
• Working mode: P mode
• Time required for track shoes Hi 36.7 ± 3.6 32.0 – 44.0
to make 5 turns after making
one initial idle turn
Lo 24.0 ± 4.8 18.9 – 31.0
Travel speed
Mi sec. 17.1 ± 2.6 14.4 – 21.0
(Actual travel) • Hydraulic oil temperature:
• Working mode: P mode
Travel
• Flat ground Hi 13.1 – 1.3 11.7 – 15.1

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

45 – 55°C
• Travel speed: Hi
Travel deviation mm Max. 200 Max. 300
• Run up for at least 10 m, and
measure deviation when traveling
next 20 m on flat ground
a Use a hard flat ground
a Measure dimension (χ)
PC400/450(LC)-7 20-15
(9)
Cate-
gory
Hydraulic drift of travel • Engine stopped mm 0 0

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

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

movement at tip of bucket teeth
• Bucket: mm
Rated load 21.2 kN {2,160 kg}
Arm cylinder • Horizontal flat ground
(cylinder extension • Levers at neutral Max. 85 Max. 128
amount) • Engine stopped
45 – 55°C
• Start measuring immediately after
Bucket cylinder setting
(cylinder retraction • Measure hydraulic drift every 5 Max. 30 Max. 45
amount) minutes, and judge from results
for 15 minutes
20-16 PC400/450(LC)-7
(9)
Cate-
gory
Boom
RAISE
4.7 ± 0.5 Max. 5.7
Bucket teeth in
contact with ground
LOWER
Cylinder fully • Hydraulic oil temperature:
45 – 55°C 3.7 ± 0.4 Max. 4.5
extended
• In A mode
Arm
CURL
2.6 ± 0.3 Max. 3.2
Cylinder fully
retracted

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

Cylinder fully
retracted

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

Cylinder fully
retracted

CLOSE
Fully extended • Hydraulic oil temperature:

45 – 55°C 2.1 ± 0.3 Max. 2.7
• In A mode
PC400/450(LC)-7 20-17
(9)
Cate-
gory
Boom Max. 3.0 Max. 5.0
• Lower boom and measure time

taken from point where bucket
contacts ground to point where
chassis rises from ground
• Engine at low idle
• Hydraulic temperature: 45 – 55°C
Arm Max. 3.0 Max. 5.0

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

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

• Time taken for bottom dump to
move again when operated from
max. bottom open position to
close position and stopped tem-
porarily
45 – 55°C
20-18 PC400/450(LC)-7
(9)
Cate-
gory
Internal leakage
Cylinders • Hydraulic oil temperature: Max. 4.5 Max. 20

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

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

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

hydraulic pump
Performance of
Piston pump
Hydraulic pump
See next page l/min See next page
delivery
PC400/450(LC)-7 20-19
(9)
Cate- Permissible
Item Measurement Condition Unit Standard value
gory value
Discharge amount of hydraulic pump (A mode)

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

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

2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
20-20 PC400/450(LC)-7
(9)
TESTING AND ADJUSTING
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE ...................................................... 20-102
MEASURING ENGINE SPEED .................................................................................................................. 20-104
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-105
MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-106
MEASURING EXHAUST GAS COLOR ...................................................................................................... 20-107
ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-108
MEASURING COMPRESSION PRESSURE.............................................................................................. 20- 110
MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 112
MEASURING ENGINE OIL PRESSURE .................................................................................................... 20- 113
HANDLING OF FUEL SYSTEM DEVICES................................................................................................. 20- 114
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM .................................................................. 20- 114
MEASURING FUEL PRESSURE ............................................................................................................... 20- 115
BLEEDING AIR FROM FUEL CIRCUIT ..................................................................................................... 20- 116
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE .................................................................................... 20- 118
ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20- 119
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION ........................................ 20-120
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................ 20-121
MEASURING CLEARANCE OF SWING CIRCLE BEARING..................................................................... 20-122
TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................. 20-123
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
SWING, AND TRAVEL CIRCUITS....................................................................................................... 20-124
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT ....................................................................... 20-128
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ................................... 20-129
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................... 20-132
MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-137
MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-140
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................ 20-142
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT ................................... 20-143
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.............................................................. 20-145
MEASURING OIL LEAKAGE...................................................................................................................... 20-146
BLEEDING AIR FROM EACH PART.......................................................................................................... 20-149
TESTING PROCEDURE OF DIODE .......................................................................................................... 20-152
SPECIAL FUNCTIONS OF MONITOR PANEL .......................................................................................... 20-153
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL ............................................................... 20-179-2
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER ................................................. 20-180
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM .......... 20-181
PM-CLINIC SERVICE ................................................................................................................................. 20-183
PC400/450(LC)-7 20-101
(7)
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
symbol
Q’ty
Testing/Adjusting item Part No. Part name Remarks
Measuring intake air pres-

A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
sure (boost pressure)
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
1 799-201-1502 Handy smoke meter 1

Pollution level: 0 – 70 % (With standard
Measuring exhaust gas
C color)
color
Commercially (Pollution level × 1/10 Bosch index)
2 Smoke meter 1
available
Commercially Air intake side: 0.35 mm, Exhaust side:

Adjusting valve clearance D Feeler gauge 1
available 0.57 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Measuring compression 795-471-1410 Adapter 1

E 2 For 125E-3 engine
pressure 6217-71-6112 Gasket 1
3 795-799-1170 Puller 1
Measuring blow-by pres-
F 799-201-1504 Blow-by checker 1
sure
(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil
G
pressure 790-261-1203 Digital hydraulic tester 1 (Pressure gauge): 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 (Pressure gauge): 0.98MPa {10 kg/cm2}
1
Measuring fuel pressure H 790-261-1203 Digital hydraulic tester 1 Same as G
2 799-401-2320 Hydraulic tester 1
Measuring clearance of Commercially
J Dial gauge 1 with magnet
swing circle bearing available
Measuring and adjusting oil 1 Same as G
pressures in work equip- 790-261-1203 Digital hydraulic tester 1
k
ment, swing, and travel cir- 799-101-5220 Nipple 2
cuits 2 (Size): 10 × 1.25 mm
07002-11023 O-ring 2
1 Same as G1
Measuring basic pressure 790-261-1203 Digital hydraulic tester 1
L
in control circuit 799-101-5220 Nipple 2
2 Same as K2
07002-11023 O-ring 2
1 Same as G
Testing and adjusting oil 790-261-1203 Digital hydraulic tester 1
pressure in pump PC M
control circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
20-102 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
symbol
Q’ty
Testing/Adjusting item Part No. Part name Remarks

1 Same as G1
790-261-1203 Digital hydraulic tester 1
Testing and adjusting
799-101-5220 Nipple 4
pressure in pump LS N 2 Same as M2
control circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
1 Same as G1
Measuring solenoid valve 790-261-1203 Digital hydraulic tester 1
P
output pressure 799-401-3100 Adapter 1 (Size): 02
2
799-401-3200 Adapter 1 (Size): 03
Measuring PPC valve 1 Same as G1
Q 790-261-1203 Digital hydraulic tester 1
output pressure
2 970-301-1740 Joint 1 (Size): PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
Testing wear of sprocket — 799-627-1120 Wear gauge 1
Measuring coolant and oil
— 799-101-1502 Digital thermometer 1 Same as B
temperatures
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

—
and pressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work equip- Commercially
— Stopwatch 1
ment speed available
Measuring voltage and Commercially
— Tester 1
resistance available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
PC400/450(LC)-7 20-103
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

1. Turn the starting switch ON and set the monitor 4) Measuring 2-pump relief + one-touch power
panel to “Monitoring”. maximizing speed (near rated speed):
a For the operating method, see “Special func- i) Start the engine and set the fuel control
tions of monitor panel”. dial in the high idling position (MAX).
• Monitoring code: 01002 Engine Speed ii) Set the working mode switch in the A-
01006 Engine Speed mode position.
a Code 01002 is information of the engine control- iii) While relieving the arm circuit by moving
ler and code 01006 is information of the pump the arm in, keep pressing the one-touch
controller. The engine speed can be measured power maximizing switch.
with either of those codes. a The one-touch power maximizing func-
a The engine speed is displayed in rpm. tion is reset automatically in about 8.5
seconds even if the switch is kept held.
Accordingly, measure the engine speed
in that period.
5) Measuring auto-deceleration speed
1) Start the engine and set the fuel control
dial in the high idling position (MAX).
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control and
swing control levers in neutral.
a The engine speed lowers to a certain
level about 5 seconds after all the levers
are set in neutral. This level is the auto-
deceleration speed.
2. Run the engine and raise engine coolant and

hydraulic oil temperatures to operating range.
3. Measure the engine speed under each meas-

urement condition.
1) Measuring low idling speed:
i) Start the engine and set the fuel control
dial in the low idling position (MIN).
ii) Set the work equipment control, swing
control, and travel levers in neutral and
measure the engine speed.
2) Measuring high idling speed:
ii) Set the working mode switch in the A-
mode position.
iii) Turn the auto-decelerator switch OFF.
iv) Set the work equipment control, swing
control, and travel levers in neutral.
3) Measuring 2-pump relief speed:
ii) Set the working mode switch in the A-
mode position.
iii) Relieve the arm circuit by moving the
arm in.
20-104 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure 4. Run the engine and raise engine coolant and
(boost pressure) hydraulic oil temperatures to operating range.
Symbol Part No. Part Name 5. Set the working mode switch in the A-mode
position.
A 799-201-2202 Boost gauge kit
6. While running the engine at high idling, relieve
a When installing and removing the measuring the boom circuit by raising the boom and meas-
instruments, take care not to touch a hot part of ure the intake air pressure (boost pressure).
the engine.
1. Open the engine hood and remove intake air

pressure pick-up plug (1).
7. After finishing measurement, remove the meas-

uring instruments and return the removed parts.
2. Install nipple [1] of boost gauge kit A and con-

nect gauge [2].
3. Run the engine at a medium or higher speed

and drain the oil from the hose.
a Insert the connecting parts of the gauge and
hose about a half and open the self-seal on
the hose side repeatedly, and the oil will be
drained.
a If Pm kit A is available, you may drain the oil
by using the air bleeding coupling (790-261-
1130) in the kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
PC400/450(LC)-7 20-105
(1)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

a Measuring instrument of exhaust gas tempera- 5. Procedure for measuring exhaust temperature
ture periodically for preventive maintenance (Pm
Clinic), etc.
Symbol Part No. Part Name 1) Set the working mode switch in the A-mode
position.
B 799-101-1502 Digital thermometer
2) Run the engine at high idling, relieve the
k Install and remove the measuring instrument af-

arm circuit by moving the arm in, and meas-
ure the exhaust temperature.
ter the exhaust manifold is cooled. a Measure the exhaust temperature after
it is stabilized.
1. Open the engine hood and remove exhaust
temperature pick-up plug (1).

2. Install sensor [1] of digital thermometer B and
connect them to meter [2].
a Clamp the wiring harness of the digital ther-
mometer so that it will not touch a hot part.

4. Procedure for measuring maximum exhaust

temperature for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Set the digital thermometer in the PEAK
mode.
20-106 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instrument of exhaust gas color
Symbol Part No. Part Name

1 799-101-9000 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing and removing the measuring in-

struments, take care not to touch a hot part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2. 2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smoke
1. Measuring with handy smoke checker C1 meter C2.
1) Stick a sheet of filter paper to C1. a Limit the supplied air pressure to 1.5
2) Insert the exhaust gas intake pipe in MPa {15 kg/cm2}.
exhaust pipe (1). 3) Connect the power cable to a receptacle of
3) Run the engine and raise engine coolant AC 100 V.
temperature to operating range. a Before connecting the cable, check that
4) Accelerate the engine suddenly or run it at the power switch of the smoke meter is
high idling and operate the handle of smoke turned off.
checker C1 so that the filter paper will 4) Loosen the cap nut of the suction pump and
absorb the exhaust gas. fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
C2.
5) Remove the filter paper and compare it with

the attached scale.
6) After finishing measurement, remove the
m ea su ri ng i ns tr um ent an d re tur n the
removed parts. 6) Run the engine and raise engine coolant
temperature to operating range.
2. Measuring with smoke meter C2 7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal
1) Insert probe [1] of smoke meter C2 in the of smoke meter C2 and collect the exhaust
outlet of exhaust pipe (1) and fix it to the gas into the filter paper.
exhaust pipe with a clip. 8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
me as ur in g in str u men t a nd r etu r n t he
removed parts.
PC400/450(LC)-7 20-107
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

the compression top dead center. In this
a Adjusting instrument for valve clearance case, rotate the crankshaft one more turn.

Commercially
D Feeler gauge
available
1. Open the engine hood and remove all cylinder

head covers (1).
a Remove all the intermediate clamps of the
fuel high-pressure tube and disconnect the
sleeve nuts on the common rail side and in-
jector side, and you can remove the cylinder
head covers.
a Use ring wrenches (on the market) for high-
pressure pipes to disconnect and connect 5. Insert feeler gauge D in clearance “b” between
the fuel high-pressure tubes. rocker arm (3) and crosshead (4) and adjust the
a Remove the air intake connector, too, from valve clearance with adjustment screw (5).
the top of the No. 1 cylinder head cover. a With the feeler gauge inserted, turn the ad-
a After removing the head covers, tighten the justment screw to a degree that you can
sleeve nuts temporarily so that the fuel high- move the filler gauge lightly.
pressure tubes will not interfere with the
rocker arms.
3 Locknut:
6. Fix adjustment screw (5) and tighten locknut (6).
53.0 – 64.7 Nm {5.4 – 6.6 kgm}

a After tightening the locknut, check the valve
clearance again.
2. Remove the belt protection covers (2 pieces)

and loosen the fan belt and alternator belt.
3. Remove the radiator undercover.

7. Turn the crankshaft forward by 120° each time
4. Rotate the crankshaft forward to bring the and repeat steps 2 – 5 for each cylinder accord-
stamped “1.6TOP” line “a” of the damper to ing to the firing order.
pointer (2) and set the No. 1 cylinder to the com- • Firing order: 1 – 5 – 3 – 6 – 2 – 4
pression top dead center.
a Crank the crankshaft with the crank pulley
mounting bolt (width across flats: 24 mm)
only in the forward direction so that the bolt
will not be loosened.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not at
20-108 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:

9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a After tightening the sleeve nuts permanently,
tighten the clamp bolts of the fuel high-pres-
3 Fuel high-pressure tube sleeve nut:

sure tubes permanently.
3 Fuel high-pressure tube clamp bolt:

39.2 – 49.0 Nm {4 – 5 kgm}
3 Air intake connector clamp:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9.8 ± 0.5 Nm {100 ± 5 kgcm}

a Adjust the belt tension. For details, see
TESTING AND ADJUSTING FAN BELT
AND ALTERNATOR BELT TENSION.
PC400/450(LC)-7 20-109
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pressure

1 795-502-1590 Compression gauge
795-471-1410 Adapter
E 2
6217-71-6112 Gasket
3 795-799-1170 Puller
k When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
4. Install adapter E2 and connect it to compression
3 Holder mounting bolt:

1. Run the engine and warm up the engine oil tem- gauge E1.
perature to 40 – 60°C.
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2. Open the engine hood and remove cover (1) of
the cylinder head to be measured.
a Remove all the intermediate clamps of the
fuel high-pressure tube and disconnect the
sleeve nuts on the common rail side and in-
jector side, and you can remove the cylinder
head cover.
a Use ring wrenches (on the market) for high-
pressure pipes to disconnect and connect
the fuel high-pressure tubes.
a Remove the air intake connector, too, from
the top of the No. 1 cylinder head cover.
5. Adjust the valve clearance. For details, see

ADJUSTING VALVE CLEARANCE.
6. Remove the engine undercover and disconnect

engine intermediate connectors ER02 and
ER03.
k If the connectors are not disconnected, the
engine starts during measurement, and that
is dangerous. Accordingly, be sure to dis-
k Cover the connectors on the controller side

connect the connectors.
(chassis side) with a vinyl sheet, etc. to pre-

3. Using puller E3, remove injector (2). vent electric leakage and grounding fault.
a Loosen the nuts of the wiring harness alter-
nately. 7. Turn the starting switch ON and prepare the
a After removing the injector, tighten the monitor panel for measuring engine speed.
sleeve nut temporarily so that the fuel high- a See MEASURING ENGINE SPEED.
pressure tube will not interfere with the rock-
er arm.
20-110 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
8. Crank the engine with the starting motor and

measure the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
a While measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.
3 Injector holder mounting bolt:

3 Cylinder head cover mounting bolt:

58.8 – 73.5 Nm {6.0 – 7.5 kgm}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

a After tightening the sleeve nuts permanently,
tighten the clamp bolts of the fuel high-pres-
3 Fuel high-pressure tube sleeve nut:

sure tubes permanently.
3 Fuel high-pressure tube clamp bolt:

39.2 – 49.0 Nm {4 – 5 kgm}
3 Air intake connector clamp:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9.8 ± 0.5 Nm {100 ± 5 kgcm}
PC400/450(LC)-7 20-111
(1)
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instrument for blow-by pressure

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

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

4. Run the engine at high idling and measure the

blow-by pressure under the following condition.
• Work equipment mode: A
• Swing lock switch: ON (High pressure relief)
• Work equipment, swing, and travel circuits:
Relieve by moving arm in.
a Read the blow-by checker when its
pointer is stabilized.

20-112 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
G 790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Open the engine hood and remove oil pressure

pick-up plug (1) from the engine cylinder block.

2. Install nipple [1] of hydraulic tester G1 and con-

nect it to hydraulic tester G2.
3. Run the engine and raise engine coolant tem-

perature to operating range.
4. Measure the engine oil pressure at low idling

and high idling.
PC400/450(LC)-7 20-113
(1)
HANDLING OF FUEL SYSTEM DEVICES
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
HANDLING OF FUEL SYSTEM RELEASING RESIDUAL

DEVICES PRESSURE FROM FUEL
SYSTEM
a Precautions for testing and adjusting fuel sys-
tem a Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) and high-pressure circuit of the fuel system
consists of more precise parts than the conven- while the engine is running.
tional fuel injection pump and nozzle. If foreign Low-pressure circuit: Feed pump – Fuel filter –
matter enters this system, it can cause a trouble. Fuel supply pump
When testing and adjusting the fuel system, High-pressure circuit: Fuel supply pump – Com-
take care more than the past. If dust, etc. sticks mon rail – Fuel injector
to any part, wash that part thoroughly with clean a The pressure in both low-pressure circuit and
fuel. high-pressure circuit lowers to a safety level
a Precautions for replacing fuel filter cartridge automatically 30 seconds after the engine is
Always use a Komatsu genuine fuel filter car- stopped.
tridge. a Before the fuel circuit is tested and its parts are
Since the common rail fuel injection system removed, the residual pressure in the fuel circuit
(CRI) consists of more precise parts than the must be released completely. Accordingly,
conventional fuel injection pump and nozzle, it observe the following.
k Before testing the fuel system or removing
employs a high-efficiency special filter to pre-
vent foreign matter from entering it.
If a filter other than a Komatsu genuine filter is its parts, wait at least 30 seconds after stop-
used, the fuel system may have trouble. So ping the engine until the residual pressure in
never use any thing but a Komatsu genuine fil- the fuel circuit is released. (Do not start the
ter. work just after stopping the engine since
there is residual pressure.)
20-114 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

a Measuring instruments for fuel pressure 3. Run the engine at high idling and measure the
fuel pressure.
Symbol Part No. Part Name a If the fuel pressure is in the following range,
it is normal.
1 0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
H 790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure only the fuel pressure in the low-pres-

sure circuit from the feed pump to the fuel filter
and fuel supply pump.
k Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be meas-
ured.
1. Open the engine hood and remove fuel pres-

sure pick-up plug (1).
2. Install nipple [1] of hydraulic tester H1 and con-

nect them to hydraulic tester H2.
PC400/450(LC)-7 20-115
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
a If fuel is used up or if a fuel circuit device is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
a Open the engine hood.
1. Remove fuel filter (1) and fill it with fuel and

install it again.
a Fill the fuel filter with clean fuel and take care
that dirt will not enter it.
a Add fuel through inlet ports (1a) (8 places) of
the filter. Since hole (1b) is the outlet port
(clean side), do not add fuel through it.
a If clean fuel is not available, do not remove 2. Remove plug (2a) of the fuel filter and operate
the filter but fill it with the fuel from the fuel priming pump (3).
tank by operating the priming pump. a Operate the priming pump until the fuel flows
3 Plug: 3.9 – 6.9 Nm {0.4 – 0.7 kgm}

out of the plug hole and install the plug.
20-116 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Remove air bleed plug (2b) of the fuel filter and

operate priming pump (3).
a Operate the priming pump until the fuel flows
3 Air bleed plug:

out of the plug hole and install the plug.
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeder (4) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.
a Operate the priming pump until fuel flows
from air bleeder (2b) and tighten the air
bleeder. Then operate the priming pump
3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}

several more times, until it becomes heavy.
5. Start the engine with the starting motor.

a Air in the high-pressure circuit is automati-
cally bled when the engine is cranked.
a If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above procedure from step 2.
PC400/450(LC)-7 20-117
(1)
TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

k Very high pressure is generated in the high- 9. Inspect the fuel piping and devices for fuel leak-
pressure circuit of the fuel system. If fuel leaks age.
while the engine is running, it is dangerous a Inspect around the high-pressure circuit
since it can catch fire. parts coated with the color checker for fuel
After testing the fuel system or removing its leakage.
parts, inspect it for fuel leakage according to the a If any fuel leakage is detected, repair it and
following procedure. inspect again from step 2.
a Clean and degrease the engine and the parts a If any fuel leakage is not detected, inspection
around it in advance so that you can inspect it is completed.
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

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

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leak-

age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.
4. Run the engine at low idling.

age.
leakage.
6. Run the engine at high idling.

age.
leakage.
8. Run the engine at high idling and load it.

a Relieve the oil by moving the arm in.
20-118 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

a Adjust the engine speed sensor for the pump
controller according to the following procedure.
a The engine G speed sensor and engine Ne
speed sensor for the engine controller cannot be
adjusted.
a Open the engine hood and remove engine
speed sensor (1) before adjusting it and check
that its tip is free from steel chips and flaws, and
then install it again.
1. Screw in sensor (1) until its tip touches the tooth
2 Threads: Hydraulic sealant

tip of flywheel ring gear (2).
2. Return sensor (1) by 1/2 – 2/3 turns.

a Adjust clearance “a” between the sensor tip
and gear tooth tip to 0.75 – 1.00 mm.
3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}

3. Secure sensor (1) with nut (3).
4. After finishing adjustment, check that the moni-

tor panel displays the engine speed normally in
the monitoring mode.
a For the operating method, see “Special func-
tions of monitor panel”.
a Monitoring code: 01006 (Engine speed)
PC400/450(LC)-7 20-119
(1)
TESTING AND ADJUSTING FAN BELT AND ALTERNA-
TESTING AND ADJUSTING TOR BELT TENSION
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT

TENSION
Testing Adjusting
1. Open the engine hood and remove belt protec- a If the deflection is abnormal, adjust it according
tion covers (2 pieces). to the following procedure.
2. Press the intermediate point between alternator 1. Loosen bolts and nuts (1), (2), and (3).
pulley and fan pulley with a finger and measure
deflection “a” of the belt. 2. Turn nut (4) to move alternator (5) and adjust
a Deflection “a” when pressing force is approx- the belt tension.
imately 58.8 N {approximately 6 kg}: 13 mm a If nut (4) is
• Tightened clockwise, the belt tension is
decreased.
• Loosened counterclockwise, the belt
tension is increased.
a Check breakage of the pulleys, wear of the
V-grooves and V-belts, and contact of the
belts and V-grooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with a new belt.
3. Tighten nuts and bolts (3), (2), and (1).

a If a V-belt is replaced, readjust its tension af-
ter 1 operating hour.
20-120 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING AIR CONDITIONER COM-
TESTING AND ADJUSTING PRESSOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT TENSION
Testing Adjusting
1. Open the engine hood and remove belt protec- a If the deflection is abnormal, adjust it according
tion covers (2 pieces). to the following procedure.
2. Press the intermediate point between air condi- 1. Loosen bolts (1) and (2).
tioner compressor pulley and crank pulley with a
finger and measure deflection “a” of the belt. 2. Move compressor (3) to adjust the belt tension.
a Deflection “a” when pressing force is approxi- a Check breakage of the pulleys, wear of the
mately 58.8 N {approximately 6 kg}: V-grooves and V-belts, and contact of the
14 mm – 16 mm belts and V-grooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with a new belt.
3. Tighten bolts (2) and (1).

a If a V-belt is replaced, readjust its tension af-
ter 1 operating hour.
PC400/450(LC)-7 20-121
(1)
TESTING AND ADJUSTING MEASURING CLEARANCE OF SWING CIRCLE BEARING
MEASURING CLEARANCE OF SWING CIRCLE BEARING

a Measuring instrument for clearance of swing cir- 4. Set the arm at almost right angle to the ground
cle bearing and lower the boom until the track shoe at the
front end of the machine rises.
Symbol Part No. Part Name a At this time, the front end of the upper struc-
ture rises and the rear end lowers.
Commercially
J Dial gauge
available
5. Under this condition, read dial gauge J.
a Dial gauge J indicates the clearance of the
a When measuring the clearance of the swing cir- bearing.
cle bearing on the actual machine, observe the
following procedure.
k While measuring, do not put your hands or foot
under the undercarriage.
1. Fix dial gauge J to outer race (1) or inner race

(2) of the swing circle and apply the probe to the
end face of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge J on the front or at rear side
of the machine.
6. Return the machine to the position of step 2 and

check that dial gauge J indicates 0 again.
a If dial gauge J does not indicate 0, repeat
steps 3 – 5.
2. Set the work equipment in the maximum reach

position and set the bucket tip at the height of
the revolving frame bottom.
a At this time, the front end of the upper struc-
ture lowers and the rear end rises.
3. Set the dial gauge to 0 point.
20-122 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing Adjusting
1. Run the engine at low idling and move the a If the track shoe tension is abnormal, adjust it
machine forward by the length of track on according to the following procedure.
ground and stop slowly.
1. When tension is too high
2. Place square bar [1] on the track shoe between Loosen valve (3) to discharge the grease.
k Since the valve may jump out because of
idler (1) and 1st carrier roller (2).
a As the square bar [1], use angle iron which
the high-pressure grease, do not loosen it
has less deflection.
more than 1 turn.
3. Measure maximum distance “a” between square
2. When tension is low
bar [1] and track shoe.
Add grease through valve (3).
• Standard maximum distance “a” : 10 – 30 mm
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
PC400/450(LC)-7 20-123
(1)
TESTING AND ADJUSTING OIL PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,

SWING, AND TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pres-
sure in work equipment, swing, and travel cir-
cuits

1
790-261-1203 Digital hydraulic tester
K
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
a The oil pressure in work equipment, swing, and

travel circuits can be checked with the monitor-
ing function of the monitor panel (For the operat- 2) Install nipple K2 and connect it to oil pres-
ing method, see “Special functions of monitor sure gauge [1] of hydraulic tester K1.
panel”). a Use the oil pressure gauges of 58.8 MPa
• Monitoring code: 01100 F Pump Pressure {600 kg/cm2}.
01101 R Pump Pressure
• The pump oil pressure is displayed in 1 MPa
{1 kg/cm2, 1 PSI).
3) Run the engine and raise the hydraulic oil

temperature to the operating range.
Measuring
1. Preparation work
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1) Open the pump room cover and remove oil
pressure pick-up plugs (1) and (2).
• (1): Front pump discharge pressure pick-
up plug
• (2): Rear pump discharge pressure pick-
up plug
20-124 PC400/450(LC)-7
(1)
2. Combination of pump, actuator, and valve a If the one-touch power maximizing switch is
a When the oil from the pumps is divided, the released, the valve is relieved at low pres-
front pump and rear pump act independently sure. If the former is pressed, the lower is re-
on each actuator. Note that different actua- lieved at high pressure.
tors relieve different valves. a If the swing lock switch is turned ON, the 2-
a When the work equipment circuit or swing stage relief valve is kept turned ON and the
circuit is relieved singly, the oils of the pumps valve is relieved at high pressure. Accord-
are merged. When the travel circuit is re- ingly, keep the swing lock switch turned
lieved singly, the oils of the pumps are divid- OFF.
ed.
a The actuators in the table are arranged in the 5. Measuring swing circuit relief pressure
order when the control valve is seen from the 1) Start the engine and turn the swing lock
front of the machine (and an attachment is switch ON.
installed to the service valve). 2) Run the engine at high idling and relieve the
swing circuit and measure the oil pressure.
Pump Actuator Valve relieved a The pressure measured when the swing mo-
tor safety valve is relieved is indicated.
(F unload valve) (F main relief valve)
a The swing motor relief pressure is lower than
Service Safety valve for service the main relief valve.
Boom Hi
F main relief valve 6. Measuring travel circuit relief pressure
Arm Hi
1) Start the engine and lock the travel mecha-
Front Bucket F main relief valve nism.
Left
F main relief valve k Set pin [2] between the sprocket and
travel
track frame to lock the travel mecha-
RAISE: F main relief valve nism securely.
Boom LOWER: Safety-suction
valve
(Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
Swing Swing motor safety valve
Right
Rear R main relief valve
travel
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Measuring unload pressure 2) Run the engine at high idling and relieve the
1) Start the engine. travel circuit and measure the oil pressure.
2) Run the engine at high idling and set all the
control levers in neutral and measure the oil a The pressure measured when the main relief
pressure. valve is relieved is indicated. The travel cir-
a The pressure measured when the unload cuit is always relieved at high pressure.
valve is unloaded is indicated.
4. Measuring work equipment circuit relief

pressure
1) Start the engine and move the cylinder to be
measured to the stroke end.
2) Run the engine at high idling and relieve the
cylinder and measure the oil pressure.
a The pressure measured when the main relief
valve is relieved is indicated.
PC400/450(LC)-7 20-125
(1)
Adjusting
a The unload valve cannot be adjusted.
1. Adjusting main relief pressure

a If the relief pressure of the work equipment
circuit and/or travel circuit is abnormal, ad-
just main relief valves (3) and (4) according
to the following procedure.
• (3): Front main relief valve
• (4): Rear main relief valve
a When adjusting the main relief valve on the
front pump side, remove the control valve
top cover.
a When adjusting the main relief valve on the
rear pump side, remove the control valve un- 5) Connect pilot hose (5).
dercover (if the covers are installed). 6) After finishing adjustment, check again that
a Adjust only the low relief pressure of the the pressure is normal according to the pro-
main relief valve. (If the low relief pressure is cedure for measurement described above.
adjusted, the high relief pressure is adjusted
automatically.) 2. Adjustment of boom LOWER relief pressure
a The low relief pressure is the pressure ap- (High-pressure setting side)
plied when the 2-stage relief solenoid valve a If the high relief pressure of the boom LOW-
is turned OFF and the pilot pressure is not ER circuit is abnormal, adjust the high pres-
applied to the selector port. sure setting side of boom LOWER safety-
suction valve (8) according to the following
procedure.
a The high relief pressure is the pressure ap-
plied when the machine push-up switch is
turned ON and the pilot pressure is not ap-
plied to the selector port.
1) Disconnect pilot hose (5).

2) Fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the pressure.
a If the holder is
• Turned to the right, pressure rises.
• Turned to the left, pressure lowers.
a Quantity of adjustment per turn of holder: 1) Disconnect pilot hose (9).
Approx. 20.5 MPa {Approx. 209 kg/cm2} 2) Fixing holder (10), loosen locknut (11).
3 Locknut: 49.0 – 58.8 Nm {5 – 6 kgm}

4) Fixing holder (6), tighten locknut (7). 3) Turn holder (10) to adjust the pressure.
a If the holder is
a Quantity of adjustment per turn of holder:
Approx. 25.3 MPa {Approx. 258 kg/cm2}
3 Locknut:
4) Fixing holder (10), tighten locknut (11).
93 – 123 Nm {9.5 – 12.5 kgm}
20-126 PC400/450(LC)-7
(1)
4. Adjusting swing relief pressure

a If the relief pressure of the swing circuit is ab-
normal, adjust swing motor safety valve (14)
according to the following procedure.
5) Connect pilot hose (9).

6) After finishing adjustment, check again that
the pressure is normal according to the pro-
cedure for measurement described above.
a If the high pressure setting side is adjust- 1) Fixing adjustment screw (15), loosen lock-
ed, the low pressure setting side chang- nut (16).
es. Accordingly, adjust the low pressure 2) Turn adjustment screw (15) to adjust the
setting side. pressure.
a If the adjustment screw is
3. Adjustment of boom LOWER relief pressure • Turned to the right, pressure rises.
(Low-pressure setting side) • Turned to the left, pressure lowers.
a If the low relief pressure of the boom LOW- a Quantity of adjustment per turn of adjust-
ER circuit is abnormal or the high pressure ment screw:
setting side was adjusted, adjust the low 4.70 MPa {47.9 kg/cm2}
pressure setting side of boom LOWER safe- 3) Fixing adjustment screw (15), tighten lock-
3 Locknut:
ty-suction valve according to the following nut (16).
procedure.
a The low relief pressure is the pressure ap- 147 – 196 Nm {15 – 20 kgm}
plied when the machine push-up switch is
turned OFF and the pilot pressure is applied
to the selector port.
1) Disconnect pilot hose (9).
2) Fixing holder (12), loosen locknut (13).
3) Turn holder (12) to adjust the pressure.
a If the holder is
a Quantity of adjustment per turn of holder:
Approx. 25.3 MPa {Approx. 258 kg/cm2}
3 Locknut: 78 – 93 Nm {8.0 – 9.5 kgm}

4) Fixing holder (12), tighten locknut (13).
5) Connect pilot hose (9).

6) After finishing adjustment, check again that 4) After finishing adjustment, check again that
the pressure is normal according to the pro- the pressure is normal according to the pro-
cedure for measurement described above. cedure for measurement described above.
PC400/450(LC)-7 20-127
(1)
TESTING AND ADJUSTING MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT

a Measuring instruments for basic pressure in 3. Run the engine and raise the hydraulic oil tem-
control circuit perature to the operating range.
Symbol Part No. Part Name 4. Run the engine at high idling and set all the con-
trol levers in neutral and measure the oil pres-
1 sure.
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

1. Remove the control valve top cover and remove

control circuit basic pressure pick-up plug (1).
a The figure shows the control valve seen from
inside of the pump room. 5. After finishing measurement, remove the meas-
a The relief valve for the control circuit basic
pressure is not adjustable.
2. Install nipple L2 and connect it to oil pressure

gauge [1] of hydraulic tester L1.
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.
20-128 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
TESTING AND ADJUSTING PC CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL

CIRCUIT
2) Install nipple M2 and connect it to oil pres-
a Testing and adjusting instruments for oil pressure gauge [1] of hydraulic tester M1.
sure in pump PC control circuit a Use the oil pressure gauges of 58.8 MPa
{600 kg/cm2}.
Symbol Part No. Part Name • The figure shows the pump discharge
pressure side.
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
a Before measuring the oil pressure in the pump
PC control circuit, check that the oil pressure in
the work equipment, swing, and travel circuits
and the basic pressure in the control circuit are
normal.
stop the engine. Operate the control levers sev- • The figure shows the PC valve output
eral times to release residual pressure in the pressure side.
1. Measuring PC valve output pressure (servo

piston inlet pressure)
a Measure the PC valve output pressure (ser-
vo piston inlet pressure) and pump dis-
charge pressure at the same time and
compare them.
pressure pick-up plugs (1), (2), (3), and (4).
up plug
up plug
• (3): Front PC valve output pressure pick-
up plug
• (4): Rear PC valve output pressure pick-
up plug
PC400/450(LC)-7 20-129
(1)
4) Run the engine at high idling and measure 2. Measuring PC-EPC valve output pressure
the pump discharge pressure and PC valve 1) Open the pump room cover and remove
output pressure (servo piston inlet pressure) PC-EPC valve output pressure pick-up plug
at the same time under the following condi- (5).
tion.
• Working mode: A
• Swing lock switch: ON
(2-stage relief solenoid valve is turned
ON and oil is relieved at high pressure)
• Work equipment, swing, and travel cir-
cuits: Relieve by moving arm IN.
a Judging method:
If the pump discharge pressure and PC
valve output pressure (servo piston out-
put pressure) are as follows, they are
normal.
Measured pressure Pressure ratio
Pump discharge
pressure
1 2) Install nipple M2 and connect it to oil pres-
sure gauge [1] of hydraulic tester M1.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a Use the oil pressure gauges of 5.9 MPa
{60 kg/cm2}.
a If the PC valve or servo piston is abnor-

mal, the PC valve output pressure (servo
piston output pressure) becomes “the
same as the pump discharge pressure”
or “almost 0”.
measuring instruments and return the
removed parts.

20-130 PC400/450(LC)-7
(1)
4) Set all the control levers in neutral and 2. Turn adjustment screw (9) to the right or left to
measure the oil pressure while running the adjust.
engine at low idling and high idling. a Turn the adjustment screw in the following
a If the PC-EPC valve output pressure directions.
changes as shown below, it is normal. • If the work equipment speed is low, turn
the adjustment screw to the right (to in-
Engine Control lever Oil pressure
crease the pump absorption torque).
2.94 MPa
Low idling • If the engine speed lowers, turn the ad-
{30 kg/cm2}
Neutral justment screw to the left (to decrease
0 MPa
High idling the pump absorption torque).
{0 kg/cm2}
a The adjustable range of the adjustment
screw is as follows.
5) After finishing measurement, remove the • Counterclockwise: Max. 1 turn
measuring instruments and return the • Clockwise: Max. 1 turn
removed parts.
3 Locknut:
3. Tighten locknut (8).
Adjusting
a If any of the following phenomena occurs and 27.5 – 34.3 Nm {2.8 – 3.5 kgm}
the PC valve seems to be defective, adjust PC
valves (6) and (7) according to the procedure
shown below.
• When the working load is increased, the en-
gine speed is drastically reduced.
• The engine speed is normal but the work
equipment speed is low.
• (6): Front pump PC valve
• (7): Rear pump PC valve
a The width across flats of the PC valve lock-
nut is 13 mm, and the adjustment screw (in-
side width) is 4 mm. Do not turn any other
locknuts or adjustment screws since they ef-
fect the hydraulic pumps.
4. After finishing adjustment, check that the PC
valve output pressure (servo piston inlet pres-
sure) is normal according to the procedure for
measurement described above.
1. Loosen locknut (8).

a Before loosening the locknut, make match
marks at the adjustment screw end so that
you can see the position of the locknut be-
fore the adjustment (and you can return the
locknut to its original position after turning it
in reverse).
PC400/450(LC)-7 20-131
(1)
TESTING AND ADJUSTING LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL

CIRCUIT
a Testing and adjusting instruments for oil pres- 2) Install nipple N2 and connect it to oil pres-
sure in pump LS control circuit sure gauge [1] of hydraulic tester N1.
Symbol Part No. Part Name {600 kg/cm2}.
799-101-5002 Hydraulic tester • The figure shows the pump discharge
1 pressure side.
N 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
a Before measuring the oil pressure in the pump LS
control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and the
basic pressure in the control circuit are normal.
eral times to release residual pressure in the • The figure shows the LS valve output
piping, then slowly loosen the hydraulic tank oil pressure side.
1. Measuring LS valve output pressure (servo

piston inlet pressure)
a Measure the LS valve output pressure (ser-
vo piston inlet pressure) and pump dis-
charge pressure at the same time and
compare them.
up plug
up plug
• (3): Front LS valve output pressure pick- 3) Run the engine and raise the hydraulic oil
up plug temperature to the operating range and
• (4): Rear LS valve output pressure pick- push up the track shoe on the side to be
up plug measured with the work equipment.
• When measuring front circuit: Left track
shoe
• When measuring rear circuit: Right track
shoe
k Since the track shoe pushed up will be
driven idle for measurement, secure
sufficient work area.
20-132 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS
TESTING AND ADJUSTING CONTROL CIRCUIT
2. Measuring LS differential pressure

a Measure the pump discharge pressure and
LS pressure (actuator load pressure) at the
same time and calculate the difference be-
tween them.
up plug
up plug
4) Run the engine at high idling and measure

the pump discharge pressure and LS valve
output pressure (servo piston inlet pressure)
at the same time under the following condi-
tion.
• Working mode: A
• Work equipment, swing, and travel con-
trol levers: Measure with all the levers in
neutral and measure with only the travel
lever operated halfway (with the track
shoe on one side driven idle).
a Check the safety around the machine, • (5): Front LS valve output pressure pick-
drive the track shoe pushed up idle. up plug
a Judging method: • (6): Rear LS valve output pressure pick-
If the pump discharge pressure and LS up plug
valve output pressure (servo piston out-
put pressure) are as follows, they are
normal.
Pressure ratio
Measured Travel lever
All levers
pressure operated
in neutral
halfway
Pump discharge
1
pressure Almost
LS valve output same Approx. 0.6
pressure (Approx. 3/5)

measuring instruments and return the 2) Install nipple N2 and connect it to differential
removed parts. pressure gauge N3 or the oil pressure
gauge of hydraulic tester N1.
a When using differential pressure gauge:
Connect the pump discharge pressure
to the high pressure side (back side) and
connect the LS pressure to the low pres-
sure side (lower side).
Since the differential pressure gauge
needs a 12-V power source, connect it to
a battery.
PC400/450(LC)-7 20-133
(1)
a When using oil pressure gauge:

Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
Since the differential pressure is about
2.9 MPa {30 kg/cm2} at maximum, meas-
ure it by installing the same gauge to the
pick-up plugs alternately.
• The figure shows the pump discharge
pressure side.
4) Run the engine at high idling and measure

the pump discharge pressure and LS pres-
sure (actuator load pressure) at the same
time under the following condition.
• Working mode: A
• Travel speed: Hi
• Work equipment, swing, and travel con-
trol levers: Measure with all the levers in
neutral and measure with only the travel
• The figure shows the LS valve output lever operated halfway (with the track
pressure side. shoe on one side driven idle).
a Check the safety around the machine,
drive the track shoe pushed up idle.
a Calculation of LS differential pressure
(When oil pressure gauge is used):
LS differential pressure = Pump dis-
charge pressure – LS pressure
a If the LS differential pressure is as fol-
lows, it is normal.
LS differential
Operation of lever
pressure
Unload pressure
Set all levers in
(See standard values
neutral
table)
Specified LS differen-
3) Run the engine and raise the hydraulic oil Operate travel lever
tial pressure
temperature to the operating range and halfway
(Run track shoe idle)
push up the track shoe on the side to be table)
measured with the work equipment.
• When measuring front circuit: 5) After finishing measurement, remove the
Left track shoe measuring instruments and return the
• When measuring rear circuit: removed parts.
k Since the track shoe pushed up will be
Right track shoe
driven idle for measurement, secure

sufficient work area.
20-134 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS
TESTING AND ADJUSTING CONTROL CIRCUIT
3. Measuring LS-EPC valve output pressure 4) Operate the travel speed switch and travel
1) Open the pump room cover and remove LS- lever and measure the oil pressure while
EPC valve output pressure pick-up plug (7). running the engine at high idling.
a If the LS-EPC valve output pressure
changes as shown below, it is normal.
Travel speed Travel lever Oil pressure
2.94 MPa
Lo Netral
{30 kg/cm2}
Fine opera- 0 MPa
Hi
tion (Note) {0 kg/cm2}
Note: Operate the travel lever to a

degree that the PPC oil pressure
switch is turned ON (Stop before
the machine starts traveling).

2) Install nipple N2 and connect it to oil pres-
measuring instruments and return the
sure gauge [1] of hydraulic tester N1.
removed parts.
{60 kg/cm2}.
Adjusting
a If the LS differential pressure is abnormal, adjust
LS valves (8) and (9) according to the following
procedure.
• (8): Front pump LS valve
• (9): Rear pump LS valve

1. Fixing adjustment screw (10), loosen locknut

(11).
2. Turn adjustment screw (10) to adjust the differ-
ential pressure.
a If the adjustment screw is
• Turned to the right, differential pressure
rises.
• Turned to the left, differential pressure
lowers.
a Quantity of adjustment (LS differential pres-
sure) per turn of adjustment screw:
Approx. 1.3 MPa {Approx. 13.3 kg/cm2}
PC400/450(LC)-7 20-135
(1)
3. After finishing adjustment, check that the LS

pressure is normal according to the procedure
for measurement described above.
20-136 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE

a Measuring instruments for solenoid valve output 2. Install adapter P2 and reconnect the hose.
pressure
3. Install nipple [1] of hydraulic tester P1 and con-
Symbol Part No. Part Name nect it to hydraulic gauge [2].
799-101-5002 Hydraulic tester a Use the oil pressure gauges of 5.9 MPa {60
1 kg/cm2}.
P a The figure shows the measuring instruments
799-401-3100 Adapter (Size 02) connected to the outlet hose of the 2-stage
2 relief solenoid valve.
799-401-3200 Adapter (Size 03)
a Before measuring the solenoid valve output

pressure, check that the basic pressure in the
control circuit is normal.
1. Remove the control valve top cover and discon-

nect outlet hoses (1) – (7) of the solenoid valve
to be removed.
a Since the outlet hoses of the PPC lock sole- 4. Run the engine and raise the engine oil temper-
noid valves have quick couplers on the sole- ature to the operating range.
noid valve side, measure the pressure on the
PPC valve side (on the back side of the op-
erator’s cab).
No. Solenoid valve to be measured

1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 PPC lock solenoid valve
5. Run the engine at high idling, operate the con-
trol levers and switches to turn the solenoid
valve ON or OFF, and measure the oil pressure.
a For the conditions for turning the solenoid
valve ON and OFF, see the operations table
of each solenoid valve.
a The operating condition of the solenoid valve
can be checked with the monitoring function
of the monitor panel (For the operating meth-
od, see “Special functions of machine moni-
tor”).
PC400/450(LC)-7 20-137
(1)
a If the output pressure is as follows, the sole-

noid valve is normal.
Solenoid valve Output pressure

OFF (Deenergized) 0 MPa {0 kg/cm2}
Almost same as control
basic pressure
ON (Energized)
table)

Operation table of 2nd-stage relief solenoid valve

Operating condition Operation
When overheating No. 1 setting is turned ON
OFF
When all of work equipment, swing, and travel signals are turned OFF
When swing lock switch is turned ON
When travel signal is turned ON
When in L-mode
When boom LOWER signal is turned ON ON
When signal other than swing sin-

When in A/E-mode When left knob switch gle operation signal is turned ON
is turned ON When swing single operation sig-
nal is turned ON OFF
When not under above condition
Operation table of machine push-up solenoid valve

Machine push-up OFF ON
switch ON OFF
Operation table of swing holding brake solenoid valve

When all are
OFF
Work equipment, turned OFF
swing, travel signal When one of them
ON
is turned ON
Operation table of travel speed shifting solenoid valve

When overheating No. 2 setting is turned ON
When fuel control dial is below 1,200 rpm
When travel speed switch is set to Lo
OFF
When travel signal is turned OFF
When F or R pump pressure is
When travel speed switch is set to Mi or Hi When travel signal is above 32.3 MPa {330 kg/cm }
2
turned ON When F or R pump pressure is

below 18.6 MPa {190 kg/cm2} ON
20-138 PC400/450(LC)-7
(1)
Operation table of merge-divider solenoid valve

When in B-mode When service signal is turned ON
When travel operation is performed singly
ON
above 19.6 MPa {200 kg/cm2}
When not in L-mode
When travel signal is When work equipment, OFF
below 14.7 MPa {150 kg/cm2}
turned ON switch, and service sig-
nals are turned ON When F or R pump pressure is
ON
above 16.7 MPa {170 kg/cm2}
When in L-mode
OFF
below 11.8 MPa {120 kg/cm2}
When arm IN and When F or R pump pressure is
ON
When travel signal is When swing signal is bucket CURL PPC above 24.5 MPa {250 kg/cm2}
turned OFF turned OFF pressures are above When F or R pump pressure is
1.9 MPa {19.5 kg/cm2} below 19.6 MPa {200 kg/cm2} OFF
Operation table of travel junction solenoid valve

When travel steering signal is turned ON
When travel system is When F or R pump pressure is ON
When travel steering signal is turned OFF operated singly above 34.3 MPa {350 kg/cm2}
When not under above condition OFF
Operation table of PPC lock solenoid valve

Operating condition
Lock OFF
Safety lock lever
Free ON
PC400/450(LC)-7 20-139
(1)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output
pressure

1
Q 790-261-1203 Digital hydraulic tester
2 790-301-1740 Joint (PF 1/4 + PT 1/8)

3. Install joint Q2 and nipple [1] of hydraulic tester
1. Remove the control valve top cover and opera- Q1 and connect them to oil pressure gauge [2].
tor’s cab undercover. a Use joint Q2 only when measuring the pres-
sure at the pressure sensor mounting part.
2. Disconnect PPC oil pressure switch or PPC a Use the oil pressure gauges of 5.9 MPa {60
pressure sensors (1) – (10) of the solenoid valve kg/cm2}.
to be removed. a The figure shows the measuring instruments
a If the starting switch is turned ON while the installed to the mounting part of the arm IN
arm IN or bucket CURL PPC pressure sen- PPC pressure sensor.
sor is disconnected, an electrical equipment
system error is detected. Accordingly, if the
pressure sensor is removed, reconnect it to
the connector and clamp it to the nearest
bracket.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom RAISE (S06) 7 Swing LEFT (S07)
2 Boom LOWER (S02) 8 Swing RIGHT (S03)
3 Arm IN (S04) 9 Travel (S30)
4 Arm OUT (S08) 10 Steering (S31)
5 Bucket CURL (S01) 4. Run the engine and raise the engine oil temper-
6 Bucket DUMP (S05) ature to the operating range.
20-140 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
5. Run the engine at high idling and measure the

oil pressure while the control lever of the meas-
ured circuit is in neutral and while it is operated
to the stroke end.
a If the PPC valve output pressure is as fol-
lows, the solenoid valve is normal.
Operation of lever Output pressure

In neutral 0 MPa {0 kg/cm2}
Almost same as control
Operated to basic pressure
stroke end (See standard values
table)

PC400/450(LC)-7 20-141
(1)
TESTING AND ADJUSTING ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
ADJUSTING PLAY OF WORK

EQUIPMENT AND SWING PPC
VALVES
a If the work equipment and swing levers have
excessive play, adjust them according to the fol-
lowing procedure.
1. Remove the work equipment and swing PPC

valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it

touches the heads of 4 pistons (4).
a Do not move the piston at this time.
4. Fix disc (3) and tighten locknut (2) to the speci-
3 Locknut: 98 – 127 Nm {10 – 13 kgm}

fied torque.
5. Install bellows (1).
6. Install the work equipment and swing PPC valve

assembly.
20-142 PC400/450(LC)-7
(1)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK

EQUIPMENT
a If the work equipment (cylinder) drifts hydrauli- 2. Testing arm cylinder
cally, check to see if the cause is on the cylinder 1) Stop the arm cylinder about 100 mm before
packing side or control valve side according to the IN stroke end and stop the engine.
the following procedure.
1. Testing boom cylinder and bucket cylinder

1) Set the machine in the position of measur-
ing hydraulic drift and stop the engine.
a Fill the bucket with a rated load or with
dirt and sand.
2) Operate the arm control lever in the IN posi-

tion.
• If the lowering speed is increased at this
time, the cylinder packing is defective.
• If the lowering speed does not change at
this time, the control valve is defective.
a Operate the control lever while the start-
2) When testing the boom cylinder, set the ing switch is in the ON position.
boom control lever in the RAISE position. a If the pressure in the accumulator is lost,
When testing the bucket cylinder, set the run the engine for about 10 seconds to
bucket control lever in the CURL position. heighten the pressure in the accumula-
• If the lowering speed is increased at this tor.
time, the cylinder packing is defective.
• If the lowering speed does not change at [Reference] Reason why the lowering speed is
this time, the control valve is defective. increased by the above operation
a Operate the control lever while the start- when the cylinder packing is the
ing switch is in the ON position. cause of the hydraulic drift:
a If the pressure in the accumulator is lost, 1) If the machine is set in the above position
run the engine for about 10 seconds to (where the holding pressure is applied to the
heighten the pressure in the accumula- bottom side), the oil leaks from the bottom
tor. side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod, the pressure
in the head side is increased by the oil flow-
ing in from the bottom side.
2) As the pressure in the head side is
increased, it is balanced at a certain level
(which depends on the leakage), and then
the lowering speed is lowered.
3) If the circuit on the head side is opened to
the drain circuit by the above operation of
the lever (the bottom side is closed by the
check valve at this time), the oil on the head
side flows in the drain circuit. As a result,
the pressure is unbalanced and the lowering
speed is increased.
PC400/450(LC)-7 20-143
(1)
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT
TESTING AND ADJUSTING OF WORK EQUIPMENT
3. Testing PPC valve

While the pressure in the accumulator is high,
set the safety lock lever in the LOCK/FREE
position and measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
a If there is a difference in the lowering dis-
tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).
20-144 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

1. Releasing residual pressure in hydraulic tank 3. Releasing residual pressure in swing motor
k Since the hydraulic tank is enclosed and
circuit
pressurized, release the residual pressure a The residual pressure in the swing motor cir-
in it when removing a hose or a plug con- cuit can be released by performing the oper-
nected to it. ation for RELEASING RESIDUAL
1) Lower the work equipment to the ground in PRESSURE IN HYDRAULIC CYLINDER
a stable position and stop the engine. CIRCUIT. (Operate the control lever in the
2) Loosen oil filler cap (1) of the hydraulic tank swing direction only.)
gradually to release the air in the tank.
4. Releasing residual pressure in travel motor
circuit
a Since the control valve spool of the travel mo-
tor circuit is open, the pressure in this circuit
can be released by performing RELEASING
RESIDUAL PRESSURE IN HYDRAULIC
TANK.
2. Releasing residual pressure in hydraulic cyl-

inder circuit
k When disconnecting a pipe between a hy-
draulic cylinder and the control valve, re-
lease the residual pressure in the piping
1) Release the residual pressure in the hydrau-
lic tank. For details, see RELEASING
RESIDUAL PRESSURE IN HYDRAULIC
TANK.
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch ON and set the
safety lock lever in the FREE position, then
operate the work equipment control levers
on both sides forward, backward, to the
right, and to the left.
a The control valve is operated by the pres-
sure in the accumulator. However, the ac-
cumulator pressure is released after the
control valve is operated 2 – 3 times.
3) Run the engine at low idling for 5 seconds to
heighten the pressure in the accumulator.
a When starting engine, set the safety lock
lever in the LOCK position.
4) Repeat steps 2) and 3) above 2 – 3 times,
and the residual pressure in the piping is
released.
PC400/450(LC)-7 20-145
(1)
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

a Measuring device for oil leakage 2. Measuring oil leakage from arm cylinder
1) Run the engine and raise the engine oil tem-
Symbol Part No. Part Name perature to the operating range.
Commercially 2) Move the arm cylinder to the IN stroke end
R Measuring cylinder and stop the engine.
available
k Release the residual pressure in the
1. Measuring oil leakage from boom cylinder piping on the arm cylinder head side.
1) Run the engine and raise the engine oil tem- For details, see RELEASING RESIDU-
perature to the operating range. AL PRESSURE IN HYDRAULIC CIR-
2) Move the boom cylinder to the RAISE stroke CUIT. (Operate the control lever in the
end and stop the engine. arm IN direction only.)
k Release the residual pressure in the 3) Disconnect hose (2) on the cylinder head
piping on the boom cylinder head side. side and block the hose side with a plate.
For details, see RELEASING RESIDU- k Take care not to disconnect the hose on
AL PRESSURE IN HYDRAULIC CIR- the cylinder bottom side.
CUIT. (Operate the control lever in the a Use the following part to block the hose
boom RAISE direction only.) side.
3) Disconnect hose (1) on the cylinder head 07379-01044 (Flange #10)
side and block the hose side with a plate.
k Take care not to disconnect the hose on
the cylinder bottom side.
a Use the following part to block the hose
side.
07379-01044 (Flange #10)

arm circuit by moving the arm IN.
k Take care not to “move the arm OUT”.
5) Measure the oil leakage for 1 minute after
30 seconds since relieving is started.
4) Run the engine at high idling and relieve the 6) After finishing measurement, return the
boom circuit by raising the boom. removed parts.
k Take care not to “lower the boom”.

6) After finishing measurement, return the
removed parts.
20-146 PC400/450(LC)-7
(1)
3. Measuring oil leakage from bucket cylinder 4. Measuring oil leakage from swing motor
1) Run the engine and raise the engine oil tem- 1) Run the engine and raise the engine oil tem-
perature to the operating range. perature to the operating range.
2) Move the bucket cylinder to the CURL 2) Disconnect drain hose (4) and block the
stroke end and stop the engine. hose side with a plug.
k Release the residual pressure in the
side.
piping on the bucket cylinder head side.
07376-70522 (Plug #05)
For details, see RELEASING RESIDU-
AL PRESSURE IN HYDRAULIC CIR-
CUIT. (Operate the control lever in the
arm CURL direction only.)
3) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.
k Take care not to disconnect the hose on
the cylinder bottom side.
side.
07379-01044 (Flange #10)
3) Turn the swing lock switch ON.

swing circuit by swinging.
a Measure the oil leakage for 1 minute af-
ter 30 seconds since relieving is started.
a After measuring 1 time, swing 180°, and
then measure again.
removed parts.

bucket circuit by curling the bucket.
k Take care not to “dump the bucket”.
removed parts.
PC400/450(LC)-7 20-147
(1)
5. Measuring oil leakage from travel motor

1) Remove the travel motor cover.
2) Run the engine and raise the engine oil tem-
perature to the operating range, and then
lock the travel system and stop the engine.
k Put pin [1] between the sprocket and
track frame to lock the travel system se-
curely.
3) Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.
side.
07376-70522 (Plug #05)

travel circuit.
k Wrong operation of the lever can cause
an accident. Accordingly, make signs
and checks securely.
a Measure the oil leakage for 1 minute af-
ter 30 seconds since relieving is started.
a Measure several times, moving the mo-
tor a little (changing the position of the
valve plate and cylinder and that of the
cylinder and piston) each time.
removed parts.
20-148 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART

Air bleeding procedure
1 2 3 4 5 6
Air bleeding item Bleeding Bleeding Bleeding Check oil
Bleeding
air from Starting air from air from level and
air from
Work hydraulic engine swing travel starting
cylinder
pump motor motor work
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q q
• Replacing and repairing hydrau-

lic pump q q q q
• Removing suction piping
• Replacing and repairing control
valve q q q
• Removing control valve piping
• Replacing and repairing cylinder
q q q
• Removing cylinder piping
• Replacing and repairing swing
motor q q q
• Removing swing motor piping
• Replacing and repairing travel
motor q q q
• Removing travel motor piping
• Replacing and repairing swivel
joint q q
• Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump
1) Loosen bleeder (1) and check that oil flows
out.
2) If the oil does not flow out, disconnect drain
hose (2) and fill the pump case with oil
through the drain port.
a Fix the drain hose adapter to a place
higher than the oil level in the hydraulic
tank.
a Fill the pump case with oil until oil con-
taining no bubbles flows out of the bleed-
er.
3) After oil containing no bubbles flows out of
3 Air bleeder:
bleeder (1), tighten air bleeder (1).
2. Starting engine
7.8 – 9.8 Nm {0.8 – 1.0 kgm} When running the engine after performing step
a If the drain hose has been disconnected, 1, keep its speed at low idling for 10 minutes.
connect it after tightening the air bleeder. a If the engine coolant temperature is low and
the automatic warm-up operation has start-
ed, stop the engine temporarily and reset the
automatic warm-up operation with the fuel
control dial. (Set the starting switch to the ON
position and hold the fuel control dial in the
MAX position for 3 seconds, the automatic
warm-up operation is reset.)
PC400/450(LC)-7 20-149
(1)
3. Bleeding air from cylinder 5. Bleeding air from travel motor

a If a cylinder was replaced, bleed air from it 1) Remove the travel motor cover.
before connecting the work equipment. In 2) Run the engine at low idling.
particular, the boom cylinder does not move 3) Loosen bleeder (4) and check that oil flows
to the lowering stroke end, if it is installed to out.
the work equipment. 4) After oil containing no bubbles flows out,
3 Bleeder:
1) Run the engine at low idling for about 5 min- tighten bleeder (4).
utes.
2) Running the engine at low idling, raise and 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
lower the boom 4 – 5 times.
a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3) Running the engine at high idling, perform
step 2).
4) Running the engine at low idling, move the
piston rod to the stroke end and relieve the
oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor

1) Run the engine at low idling.
2) Loosen hose (3) of port S slowly and check
that oil flows out. 5) Using the work equipment, raise the track
k At this time, do not perform the swing- shoe on either side.
ing operation. 6) Drive the raised track shoe idle slowly for
3) If the oil does not flow out, stop the engine about 2 minutes.
and disconnect the hose of port S and fill the a Drive the track shoe on the opposite side
pump case with oil. idle similarly.
a After filling the pump case with oil, con-
nect the hose of port S, and then repeat
steps 1) and 2).
4) After oil containing no bubbles flows out,
tighten the hose of port S.
5) Slowly swing 2 turns or more in each direc-
tion.
20-150 PC400/450(LC)-7
(1)
6. Check oil level and starting work

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

hydraulic tank.
a If the oil level is between lines H and L,
it is normal.
a If the oil level is below line L, add new oil.
PC400/450(LC)-7 20-151
(1)
TESTING AND ADJUSTING TESTING PROCEDURE OF DIODE
TESTING PROCEDURE OF DIODE

a Test an assembled-type diode or a diode unit
a The conductive direction of an assembled-type
diode is marked as shown in the figure.
a The conductive direction of each diode is
marked on its surface.
2. When using an analog tester

1) Set the tester in the resistance range.
2) Apply the test pins as shown and check
movement of the pointer.
i) Apply the red (+) test pin to the anode
(P) side of the diode and the black (–)
test pin to the cathode (N) side.
ii) Apply the red (+) test pin to the cathode
(N) side of the diode and the black (–)
test pin to the anode (P) side.
3) Judge the condition of the diode from move-
ment of the pointer.
• The pointer does not move in step i)
above but moves in step ii): Normal
(Moving angle (resistance) depends on
the type and measurement range of the
tester)
• The pointer moves in both step i) and
step ii): Defective (Internal short circuit)
1. When using a digital tester • The pointer does not move in either step
1) Set the tester in the diode range and check i) or step ii): Defective (Internal discon-
the indicated value. nection)
a If an ordinary tester is used, the voltage
of the battery in itself is indicated.
2) Apply the red (+) test pin to the anode (P)
side of the diode and the black (–) test pin to
the cathode (N) side and read the indicated
value.
3) Judge the condition of the diode from the
indicated value.
• The indicated value does not change:
There is no continuity (Defective).
• The indicated value changes: There is
continuity (Normal) (Note).
Note: In the case of a silicon diode, the
tester indicates a value of 460 – 600.
20-152 PC400/450(LC)-7
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
SPECIAL FUNCTIONS OF MONITOR PANEL
[1] Numeral input switch 1 [6] Numeral input switch 6 [ ] Return switch
[2] Numeral input switch 2 [7] Numeral input switch 7 [ ] Move-up switch
[3] Numeral input switch 3 [8] Numeral input switch 8 [ ] Move-down switch
[4] Numeral input switch 4 [9] Numeral input switch 9 [ ] Input check switch
[5] Numeral input switch 5 [0] Numeral input switch 0
PC400/450(LC)-7 20-153
(1)
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on the multi-display unit.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu
The items in this menu are displayed normally. The operator can display and set them by operating
switches.
2. Special functions: Service menu
The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches.
Operator’s Menu Service Menu

1 Function of inputting and setting password 16 Function of monitoring [01]
2 Screen to display KOMATSU logo Function of Electrical system
17 abnormality
3 Function of check before starting record [02] Mechanical system
4 Function of displaying maintenance items 18 Function of maintenance record [03]

5 Function of displaying caution items 19 Function of maintenance mode change [04]
Function of checking working mode and
6 20 Function of phone No. entry [05]
travel speed
7 Function of displaying ordinary screen Mode in which key is ON
Function of adjusting brightness and contrast
8 Language
of display Function of
Function of adjusting flow rate for breaker 21 initial setting
9 and default [06] Unit
and attachments
Function of checking maintenance informa-
10 With/Without service circuit
tion
11 Function of displaying service meter Pump absorption torque
Function of Adjustment of flow for
22
12 Function of checking display LCD adjustment [07] attachment during com-
pound operation
Function of cylinder cut out mode operation
13 Function of displaying cautions 23
[09]
14 Function of displaying user code
Function of displaying error code and failure
15
code
20-154 PC400/450(LC)-7
(1)
Operation and display of Operator ’s

Menu (Outline)
a Only outline of the operating method is
described in this section. For details of contents
and operation of each menu, see OPERATION
MANUAL or the volume of STRUCTURE AND
FUNCTION.
1. Function of inputting and setting password

When the starting switch is turned ON, the
screen to input a password is displayed.
a This screen is displayed only when the pass-
word function is set.
2. Screen to display KOMATSU logo

When a password is input (if it is set) or when
the starting switch is turned ON, the KOMATSU
logo is displayed for 2 seconds.
3. Function of check before starting

After the KOMATSU logo is displayed, the
screen for check before starting is displayed for
2 seconds.
4. Function of displaying maintenance items

After the screen for check before starting is dis-
played, if any oil or filter is near or has passed
the set maintenance time, the maintenance
mark is displayed for 30 seconds.
a This screen is displayed only when the main-
tenance function is set.
PC400/450(LC)-7 20-155
(1)
5. Function of displaying caution items

played, if any check item is abnormal, the corre-
sponding symbol mark is displayed.
6. Function of checking working mode and trav-

el speed
played, the symbol marks of the working mode
and travel speed are displayed in large size for 2
seconds to urge the operator to check the set-
ting.
7. Function of displaying ordinary screen

After the screen for checking the working mode
and travel speed is displayed, the ordinary
screen is displayed.
a When the ordinary screen is displayed, if the
working mode or travel speed is changed or
if the auto deceleration or windshield wiper is
set effective, the corresponding symbol mark
is displayed in large size for 2 seconds.
a The preheating monitor is displayed only
when the preheater is turned ON.
8. Function of adjusting brightness and con-

trast of display
The operator can adjust the brightness and con-
trast of the display with the screen adjustment
switches.
20-156 PC400/450(LC)-7
(1)
9. Function of adjusting flow rate for breaker

and attachments
(for machine with breaker or attachment)
The operator can adjust the pump flow rate for
the breaker or an attachment with the selector
switch.
a The symbol marks and description of the
breaker and attachment shown on the
screen are partly different.
10. Function of checking maintenance informa-

tion
The operator can check the detailed information
about the maintenance items (set time and
elapsed time) and reset them after checking
with the maintenance switches.
a The maintenance function is set and reset
and the maintenance time is set with the
service menu.
11. Function of displaying service meter

When the starting switch is turned OFF, the
operator can display only the service meter by
operating the following switches.
• Operation of switches: [ ] + [ ] (Operate
these switches simultaneously)
12. Function of checking display LCD

On the password inputting screen or ordinary
screen, the operator can check the display LCD.
• Operation of switches: [ ] + [A] (Operate
these switches simultaneously)
a The whole LCD unit is turned ON and all the
surface becomes white. If there is not any
black part, the LCD unit is normal.
a If any switch is operated while the LCD unit
is being checked, the screen before the
check is displayed again.
PC400/450(LC)-7 20-157
(1)
13. Function of displaying cautions

If there is any abnormal item in the calculation
items, the corresponding symbol mark is dis-
played in large size for 2 seconds, then it is dis-
played in small size until the abnormal item is
repaired.
14. Function of displaying user code

If the machine has any failure, the correspond-
ing user code is displayed to urge the operator
to take a proper remedy, depending on the
degree of the failure.
a If any switch is operated while the user code
is displayed, the service code and failure
code screen appears (See 15).
a User codes and instructions given to operator

User
Failure mode Instructions given to operator
code
If the emergency pump drive switch is set in the upper (emergency) position,
E02 Error in pump control system the machine can operate normally. Have the machine inspected immediately,
however.
Set the swing holding brake release switch in the upper (release) position to
release the brake. Apply the swing brake manually with the swing lock
E03 Error in swing brake system
switch, if necessary. The brake may not be released, depending on the
cause of the failure. In any case, have the machine inspected immediately.
Error in engine controller power
supply or abnormality in engine
E10 Have the machine inspected immediately.
controller drive system circuit
(Engine stops)
Error in engine controller system Set the machine in a safe position and have the machine inspected immedi-
E11
(Engine protection output is down) ately.
Set the machine in a safe position and have the machine inspected immedi-
E14 Error in throttle system
ately.
Error in engine sensor (coolant
Although the machine can operate normally, have the machine inspected
E15 temperature, fuel temperature, or
immediately.
oil pressure)
Set the machine in a safe position and have the machine inspected immedi-
E0E Error in network
ately.
20-158 PC400/450(LC)-7
(1)
15. Function of displaying error code and failure

code
While a user code is displayed, if the following
switches are operated, the phone mark (if regis-
tered), phone No. (if registered), error code, and
failure code are displayed in order.
• Operation of switch: [ ]
a The following are displayed in order repeat-
edly as the switch is operated.
(1) Phone mark
(2) Phone No.
(3) Error code and failure code

a The phone mark and phone No. are dis-
played only when the phone No. is regis-
tered in the monitor panel. The phone No. is
registered, changed, or deleted with the
service menu.
a For details of the displayed error code and
failure code, see the error codes and failure
codes table.
PC400/450(LC)-7 20-159
(1)
Table for Error and Failure Code Nos.

Error code Failure code
division
History
code
User
Code Contents Code Component Trouble

— E112 Wiper Drive (For) S/C DY2DKB Wiper motor (Forward) Short Circuit
— E113 Wiper Drive (Rev) S/C DYDEKB Wiper Motor (Reverse) Short Circuit
Windshield Washer
— E114 Washer Drive S/C DY2CKB Short Circuit
Motor
— E115 Wiper Working Abnormality DY20KA Wiper Motor Disconnection
— E116 Wiper Parking Abnormality DY20MA Wiper Motor Malfunction
Defective communica-
— E117 Eng. Controller S-NET Comm Err. DAC0KR Engine Controller tion (Abnormality in
related component)
Defective communica-
— E118 Pump Controller S-NET Comm Err. DAB0KR Pump Controller tion (Abnormality in
related component)
Monitor CAN Communi-
E0E E128 Monitor Comm. Abnormality DAFRMC Defective Operation
cation
Travel Neutral Solenoid
— E201 Travel Junction Sol. S/C DW91KB Short Circuit
Valve
Swing Holding Brake
E03 E203 Swing Brake Sol. S/C DW45KB Short Circuit
Solenoid Valve
Pump Merge-divider
— E204 Merge-divider Sol. S/C DWJ0KB Short Circuit
Solenoid Valve
2-stage Relief Solenoid
— E205 2-stage Relief Sol. S/C DWK0KB Short Circuit
Valve
Travel Speed Hi/Lo
Electrical system
— E206 Travel Speed Sol. S/C DW43KB Short Circuit
Selector Solenoid Valve
Travel Neutral Solenoid
— E211 Travel Junction Sol. Disc. DW91KA Disconnection
Valve
Swing Holding Brake
E03 E213 Swing Brake Sol. Disc. DW45KA Disconnection
Solenoid Valve
Pump Merge-divider
— E214 Merge-divider Sol. Disc. DWJ0KA Disconnection
Solenoid Valve
2-stage Relief Solenoid
— E215 2-stage Relief Sol. Disc. DWK0KA Disconnection
Valve
Travel Speed Hi/Lo
— E216 Travel Speed Sol. Disc. DW43KA Disconnection
Selector Solenoid Valve
Pump Controller Model
Disagreement of Model
— E217 Model Selection Abnormality DA2SKQ Selection Wiring Har-
Selection Signals
ness
Pump Controller S-NET
E0E E218 S-Net Comm. Disc. DA2SKA Disconnection
Communication
— E222 LS-EPC Sol. S/C DXE0KB LS-EPC Solenoid Valve Short Circuit
— E223 LS-EPC Sol. Disc. DXE0KA LS-EPC Solenoid Valve Disconnection
F Pump Pressure Sen-
— E224 F Pump P. Sensor Abnormality DHPAMA Malfunction
sor
R Pump Pressure Sen-
— E225 R Pump P. Sensor Abnormality DHPBMA Malfunction
sor
Pump Controller Power Lowering of Output Volt-
— E226 Press. Sensor Power Abnormality DA25KP
Supply Output age
— E227 Engine Speed Sensor Abnormality DLE2MA Engine Speed Sensor Malfunction
— E228 Service Return Relay S/C D196KB ATT Selector Relay Short Circuit
E02 E232 PC-EPC Sol. S/C DXA0KB TVC Solenoid Valve Short Circuit
20-160 PC400/450(LC)-7
(1)
division
History
code
User

E02 E233 PC-EPC Sol. Disc. DXA0KA TVC Solenoid Valve Disconnection
— E238 Service Return Relay Disc. D196KA ATT Selector Relay Disconnection
ATT Flow Throttle EPC
— E245 Service Current EPC S/C DXE4KB Short Circuit
Valve
ATT Flow Throttle EPC
— E246 Service Current EPC Disc. DXE4KA Disconnection
Valve
Arm IN PPC Pressure
— E247 Arm Curl PPC Sen. Abnormality DHS3MA Malfunction
Sensor
Bucket CURL PPC
— E248 Bucket Curl PPC Sen. Abnormality DHS4MA Malfunction
Pressure Sensor
— E251 Overload Sensor Abnormality DHX1MA Malfunction
Pump Controller CAN
E0E E257 Pump Comm. Abnormality DA2RMC Defective Operation
Communication
— E315 Battery Relay Drive S/C D110KB Battery Relay Short Circuit
Disagreement of Speed
E11 E91B Engine Ne Sensor Problem DLE3LC NE Speed Sensor
Signal
Disagreement of Speed
E11 E91C Engine G Sensor Problem DLH1LC G Speed Sensor
Signal
Engine Controller Model
E11 E920 Engine Type Selection Error DB29KQ Selection Wiring Har-
Selection Signals
ness
E11 E921 Engine Type Mismatch DB20KQ Engine Controller
Selection Signals
E14 E931 Fuel Dial sys. error DK10KX Throttle Angle Sensor Out of input signal range
Engine Coolant Temper-
Electrical system
E15 E934 Engine Coolant Sensor Hi Error DGE2KX Out of input signal range
ature Sensor
Engine Oil Pressure Disagreement of signal
E15 E936 Engine Oil Press. Sw. Error DDE2L6
Switch with operation of engine
E11 E93C Engine Boost Sensor Error DH30KX Boost Pressure Sensor Out of input signal range
Fuel Temperature Sen-
E15 E93D Engine Fuel Temp. Sensor Error DGE4KX Out of input signal range
sor
Engine Controller CAN
E0E E953 Engine Comm. Abnormality DB2RMC Defective Operation
Communication
— E954 Short Engine Starter SW. DD11KB Starter SW Short Circuit
Engine Controller S-
E0E E955 Engine S-NET error DB2SMC Defective Operation
NET Communication
Engine Controller Load Lowering of source volt-
E10 E956 Engine Power Failure (1) DB22KK
Power Supply Line age (Input)
Engine Controller Load
E15 E957 Engine Power Failure (2) D1D0KB Short Circuit
Power Supply Relay
Rotary Switch in Engine
— E95A Engine Q-adj. Sw. Signal Error DB2AMA Malfunction
Controller
Engine Coolant Temper- Disagreement of signal
E15 E96A Engine Coolant Sensor Lo Error DGE3L6
ature Sensor with operation of engine
Supply Pump (1) Sole-
E11 E970 PCV1 Over Current AD11KB Short Circuit
noid Valve
E11 E971 PCV2 Over Current AD51KB Short Circuit
noid Valve
E11 E974 PCV1 Line Cut AD11KA Disconnection
noid Valve
E11 E975 PCV2 Line Cut AD51KA Disconnection
noid Valve
Common Rail Pressure
E11 E977 Rail Press. Sensor Error DH40KX Out of input signal range
Sensor
PC400/450(LC)-7 20-161
(1)
division
History
code
User

Abnormally High Fuel
E11 E979 Rail Press. High 1 AD00L2 Common Rail
Pressure
E11 E97A Rail Press. High 2 AD00MA Common Rail Malfunction
E15 E97B Rail press. low AD10L3 Supply Pump Out of control
E11 E97C Rail press. too low AD10MB Supply Pump Lowering of Function
E11 E97D Rail Press. Out of Control AD10MA Supply Pump Malfunction
Electrical system
E11 E980 Eng. Controller Abnormality DB20KT Engine Controller Abnormality in Controller
E11 E981 Fuel Injector 1 Disc. ADA1KA Injector 1 Solenoid Valve Disconnection
E11 E982 Fuel Injector 2 Disc. ADB1KA Injector 2 Solenoid Valve Disconnection
E11 E983 Fuel Injector 3 Disc. ADC1KA Injector 3 Solenoid Valve Disconnection
E11 E984 Fuel Injector 4 Disc. ADD1KA Injector 4 Solenoid Valve Disconnection
E11 E985 Fuel Injector 5 Disc. ADE1KA Injector 5 Solenoid Valve Disconnection
E11 E986 Fuel Injector 6 Disc. ADF1KA Injector 6 Solenoid Valve Disconnection
Injector 1, 2, 3 Solenoid
E11 E98A Fuel Injector 1 – 3 S/C ADAZKB Short Circuit
Valve
Injector 4, 5, 6 Solenoid
E11 E98B Fuel Injector 4 – 6 S/C ADDZKB Short Circuit
Valve
E22 E922 Eng. Hi Out of Std A000N1 Engine Overrun
— Eng. Lo Out of Std A000N2 Engine Out of input signal range
Mechanical system
— Aircleaner Clogging AA10NX Air Cleaner Element Clogging
— Charge Voltage Low AB00KE Alternator Defective Charge
— Eng. Oil Press. Low B@BAZG Engine Oil Lowering of Oil Pressure
— Eng. Oil LvI. Low B@BAZK Engine Oil Lowering of level
— Eng. Coolant Overheat B@BCNS Coolant Overheating
— Eng. Coolant Lvl Low B@BCZK Coolant Lowering of level
— Hydr. Oil Overheat B@HANS Hydraulic Oil Overheating
a The items in this table are arranged in the order of the error codes.
a The error codes having no numbers in the user code column and the failure codes having no numbers in
the user code column and error code column are not displayed on the normal screen, even if abnormality
related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equip-
ment system or mechanical equipment system).
a The history division column shows in which division each failure is classified, the electrical equipment sys-
tem or mechanical equipment system, when it is recorded in the failure history.
a Letter “E” at the head of each error code indicates the following condition.
• With E: The failure has not been repaired yet.
• Without E: The failure has been repaired.
20-162 PC400/450(LC)-7
(1)
Operation and display of Service Menu

How to select service menu
a When using the service menu, perform the fol-
lowing special operation to change the screen.
1) Checking display
Check that the ordinary screen is displayed.
a The service menu can be selected only while
the ordinary screen is displayed.
2) Operating switches
Operate the following switches.
• Operation of switches: [ ] o [1] o [2] o [3]
(While pressing [ ], press the numeral
keys)
3) Displaying menu screen

The initial screen of the service menu is dis-
played. Select a menu which you will use.
No. Service menu
00 Return (Finish service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Maintenance mode change
05 Phone number entry
06 Initial setting/Default
07 Adjust
09 Cylinder cut out mode operation
4) Finishing menu and function

To finish the service menu screen or each menu
screen, perform one of the following operations.
(1) Press the [ ] switch (This operation is
effective on all screens).
(2) When the “Return” switch is displayed, press
it.
(3) When the “Return” menu is displayed, select
it and press the [ ] switch.
PC400/450(LC)-7 20-163
(1)
16. Function of monitoring [01]

The monitor panel monitors the signals from various
switches, sensors, and actuators installed to various
parts of the machine. The operator can display and
check the monitoring information in real time by the
following operation.
1) Selecting menu
On the initial screen of the service menu, select
“01 Monitoring” and press the [ ] switch.
2) Setting monitoring items

Select and register monitoring items with the fol-
lowing switches.
• [ ] switch: Select
• [ ] switch: Select
• [ ] switch: Register
a You can set up to 4 monitoring items (You
cannot set up to 4 monitoring items, howev-
er, depending on the selected items).
a When monitoring up to 3 items, go to the
monitoring information screen by either of
the following operations after registering
those items.
• Hold the [ ] switch (for about 3 sec-
onds).
• Select menu “99999” and press the [ ]
switch.
a If all of the settable items are registered, the
monitoring information screen appears auto-
matically after registering those items.
a For the detail, display units, etc. of the moni-
toring items, see the monitoring items table.
3) Operating for monitoring

After the monitoring infomation screen appears,
operate the machine to check the monitoring
information.
20-164 PC400/450(LC)-7
(1)
4) Function of holding monitoring information

If the [ ] switch is pressed during the monitor-
ing operation, all the monitoring information is
held. If the [ ] switch is pressed while the mon-
itoring information is held, the monitoring infor-
mation is released.
5) Function of selecting machine setting mode

To change settings of the working mode, travel
speed, or auto deceleration during the monitor-
ing operation, press the switches for those
items, and the mode checking screen appears.
a After checking the settings, press the [ ]
switch, and the monitoring screen appears
again.
a If the settings are changed during the moni-
toring operation, the new settings are held
even after monitoring is finished and the
service menu disappears and the operator
menu appears again.
PC400/450(LC)-7 20-165
(1)
Monitoring items list
Code Unit (Default: ISO)

Monitoring item Remarks
No. SI meter inch
00000 Return (Not displayed) Finish Menu
99999 To Display Screen (Not displayed) Display and Execution Menu
00200 Controller Model Select Numerals
00201 Controller Model Select Numerals
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm2 psi
01101 R Pump Pressure MPa kg/cm 2
psi
07200 Arm Curl PPC Pressure MPa kg/cm 2
psi
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi
04102 Engine Coolant Temp. Hi °C °C °F
14200 Fuel Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
01300 PC-EPC Sol. Curr. mA mA mA
01500 LS-EPC Sol. Curr. mA mA mA
01700 Service Sol. Curr. mA mA mA
03200 Battery Voltage V V V
03500 Battery Relay O/P Vol. V V V
04300 Battery Charge Vol. V V V
01006 Engine Speed r/min rpm rpm
04107 Engine Coolant Temp. Low °C °C °F
36400 Rail Pressure MPa kg/cm2 psi
36500 Boost Pressure kPa kg/cm2 psi
36700 Torque Ratio % % %
03000 Fuel Dial Vol. V V V
04200 Fuel Level Sensor Vol. V V V
04106 Engine Coolant Temp. Vol. Hi V V V
04105 Engine Coolant Temp. Vol. Lo V V V
14201 Fuel Temp. Sensor Vol. V V V
36501 Boost Press. Sensor Vol. V V V
36401 Rail Press. Sensor Vol. V V V
17200 PCV Close Angle CA CA CA
17300 Eng. Control Mode Numeral
31701 Throttle Level % % %
36100 Fuel Delivery Command mm3/st mm3/st mm3/st
36200 Rail Pressure Command MPa kg/cm2 psi
36300 Injection Timing Angle CA CA CA
20-166 PC400/450(LC)-7
(1)

No. SI meter inch
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
01900 Pressure Switch 1
Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Bucket Dump ON/OFF
01901 Pressure Switch 2
Service ON/OFF
Travel Steering ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
02300 Solenoid 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid 2 Service Return ON/OFF
Lever Sw. ON/OFF
02200 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
Model Select 1 ON/OFF
02201 Switch Input 2 Model Select 3 ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
03700 Controller Output 1 Batt. Relay Dr. ON/OFF
Key Switch ON/OFF
Start ON/OFF
04500 Monitor Input 1 Preheat ON/OFF
Light ON/OFF
Rad. Level ON/OFF
Aircleaner ON/OFF
04501 Monitor Input 2 Eng. Oil Level ON/OFF
Battery Charge ON/OFF
Swing Brake Sw. ON/OFF
Bzzr Cancel Sw. ON/OFF
04502 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
PC400/450(LC)-7 20-167
(1)

No. SI meter inch
Key SW (C) ON/OFF
Eng. Oil Press. Lo ON/OFF
Eng. Controller Eng. Oil Press. Hi ON/OFF

17400
Input Machine Sel. 1 ON/OFF
Machine Sel. 2 ON/OFF
Machine Sel. 3 ON/OFF
36800 Q Adjust Switch R (ROT-SW1) Alphanumerals
36801 Q Adjust Switch L (ROT-SW2) Alphanumerals
Pump Controller ON/OFF
05100 S-NET Connection
Eng. Controller ON/OFF
20200 Monitor Prog. Version Numerals
20212 Pump Con. Prog. Version Numerals
20209 Eng. Con. Prog. Version Numerals
a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected.
The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service
menu.
a “CA” of the unit of display denotes the crankshaft angle.
20-168 PC400/450(LC)-7
(1)
17. Function of abnormality record [02]

The monitor panel classifies and records the
past failures into the electrical system group and
mechanical system group. The operator can
display and check those failures by the following
operation.
1) Selecting menu
On the initial screen of the service menu,
select “02 Abnormality Record” and press
the [ ] switch.
2) Selecting sub-menu
On the abnormality record menu screen,
select a sub-menu and press the [ }
switch.
No. Sub-menu of abnormality record
00 Return (Finish sub-menu)
01 Electrical systems
02 Mechanical systems
3) Contents of electrical system abnormality

record screen
[1]: Reverse sequential order/Total number
of records
[2]: Error code
[3]: Failure code (Component: 4 characters,
Trouble: 2 characters)
[4]: Advance of service meter after 1st
occurrence
[5]: Contents of failure
a See “Error codes and failure codes ta-
ble” in the operator menu.
4) Contents of mechanical system abnormality

record screen
[1]: Record No.
[2]: Contents of failure
[3]: Failure code (Component: 4 characters,
Trouble: 2 characters)
[4]: Total number of occurrences
[5]: Service meter reading at 1st occurrence
a See “Error codes and failure codes ta-
ble” in the operator menu.
PC400/450(LC)-7 20-169
(1)
5) Resetting electrical system abnormality record

a Only the abnormality record of the elec-
trical system can be reset (deleted). The
abnormality record of the mechanical
system cannot be reset.
a If necessary, reset each item or all items
of the abnormality record of the electrical
system according to the following proce-
dure.
i) While the electrical system abnormality
record screen is displayed, operate the
following switches to display the reset
screen.
• Operation of switches: [ ] + [1]
[2] [3]
a This operation is the same as that
for selecting the service menu.
ii) Operate the switches according to the
direction shown on the reset screen.
a When resetting only 1 item, be sure
display it with the [ ] switch or [ ]
switch, and then perform the reset
procedure.
a When resetting all the items, you
can perform the reset procedure, re-
gardless of the item displayed on the
screen.
20-170 PC400/450(LC)-7
(1)
18. Function of maintenance record [03]

The monitor panel records the maintenance
information about the filters and oils. The opera-
tor can display and check that information by the
following operation.
1) Selecting menu
select “03 Maintenance Record” and press
the [ ] switch.
2) Displayed information
(1) Names of oils and filters
(2) Number of replacement times up to now
(3) Service meter reading at previous
replacement
PC400/450(LC)-7 20-171
(1)
19. Function of maintenance mode change [04]

The condition for setting the operation of the
maintenance display function can be changed
• Set the function effective or ineffective.
• Change the set replacement interval.
1) Selecting menu
select “04 Maintenance Mode Change” and
press the [ ] switch.
2) Selecting item to be changed

On the screen of maintenance mode chang-
ing menu, select an item to be changed.
No. Item of maintenance mode change

00 Return
01 Use/Disuse maintenance mode
02 Replacement interval of engine oil
03 Replacement interval of engine oil filter
04 Replacement interval of fuel filter
05 Replacement interval of hydraulic oil filter
Replacement interval of hydraulic tank
06
breather
Replacement interval of corrosion resistor
07
(if equipped)
08 Check and refill interval of damper case oil
09 Replacement interval of final drive case oil
10 Replacement interval of machinery case oil
11 Replacement interval of hydraulic oil
12 Return all items to initial values
a Menus “01” and “12” are used to set the

whole maintenance mode and menus
“02” – “11” are used to set the items one
by one.
3) Contents of setting of “maintenance mode

On/Off”
• On: The function of displaying all the oil
and filter items becomes effective (This
setting is applied, even if On/Off is set for
each item).
• Off: The function of displaying all the oil
and filter items becomes ineffective
(This setting is applied, even if On/Off is
set for each item).
20-172 PC400/450(LC)-7
(1)
4) Contents of setting of each item

(1) Default: Maintenance time set in monitor.
(Value recommended by manufacturer.
Constant value.)
(2) Set value: Maintenance time which oper-
ation can set freely. Monitor panel oper-
ates according to this value in
maintenance mode. (This value can be
changed by 50 hours with [ ] and [ ]
switches.)
(3) Off: Function of displaying this mainte-
nance item becomes ineffective.
(4) On: Function of displaying this mainte-
nance item becomes effective.
a The lower limit of the set time is 50 h.
5) Contents of setting “Return all items to initial

values”
If this menu is selected and the [ ] switch
is pressed, all the information items are
changed to the initial values.
PC400/450(LC)-7 20-173
(1)
20. Function of phone number entry [05]

The operator can input a phone No. and change
it according to the following procedure. Once
the phone No. is input, it and service code are
displayed alternately when the user code is dis-
played.
a If a phone No. is not input, the phone No.
screen is not displayed.
1) Selecting menu
select “05 Phone Number Entry” and press
the [ ] switch.
2) Selecting input screen

Select “Entry” to display the phone No. input
screen.
a Even if a phone No. has been registered,
if the phone No. input screen is dis-
played, the registered phone No. is
cleared.
3) Inputting and setting phone No.

On the phone No. input screen, input a
phone No. according to the following proce-
dure (The phone No. is input from the cursor
at the left end automatically).
i) Input a No. with the numeral keys from
the cursor at the left end.
ii) After finishing inputting the No., press the
[ ] switch.
a Up to 12 digits can be input. You do not
need to input a digit to an unnecessary
place, however.
a If you input a wrong No., press the [B]
switch, and the cursor returns 1 place by
1.
a If the phone No. is input, the “Entry”
screen above is displayed again. If the
phone No. is displayed on this screen, it
is input normally.
20-174 PC400/450(LC)-7
(1)
21. Function of initial setting and default [06]

The operator can change the following items
related to the monitor panel and machine, if nec-
essary.
• Working mode when starting switch is turned
ON
• Language displayed on service menu
• Unit displayed in monitoring function mode
• With/Without attachment
1) Selecting menu
select “06 Function of initial setting and
default” and press the [ ] switch.
Select a sub-menu to change its setting and
No. Sub-menu of initial value/default

00 Return (Finish initial value/default)
01 Key-on mode
02 Language
03 Unit
04 With/Without service circuit
3) Function of selecting mode when key is ON

When the starting switch is turned ON, a
working mode is displayed on the monitor
panel. The operator can change this work-
ing mode.
• A-mode, E-mode, L-mode, B-mode: If
any of these modes are set, the machine
is started in the selected mode when the
starting switch is turned ON.
• Mode when key was turned off last: If
this mode is set, the machine is started
in the mode used last when the starting
switch is turned ON.
• Initial value: If this mode is set, the ma-
chine is started in the default mode set in
the factory when the starting switch is
turned ON.
a If the machine having an attachment is
stopped in the B-mode, it is started in the
B-mode when the starting switch is
turned ON next time, regardless of this
setting.
PC400/450(LC)-7 20-175
(1)
4) Function of setting language

The operator can select Japanese or
English as the language displayed on the
service menu.
a The default language of the monitor pan-
el is English.
a When using a spare monitor panel in the
Japanese language area, select Japa-
nese with this function.
5) Function of selecting unit

The operator can select 1 of the 3 unit sys-
tems as the unit system used for the data
displayed by the monitoring function of the
service menu.
a The default unit system of the monitor
panel is the SI unit system.
6) Function of selecting “with/without service

circuit”
The operator can set “with/without service
circuit”.
• With service circuit: When attachment is
installed
• Without service circuit: When attach-
ment is not installed.
a When an service circuit is installed, if
“With service circuit” is not set on this
screen, the operator cannot use the se-
lect function (adjustment of oil flow for
the attachment) in the operator mode.
20-176 PC400/450(LC)-7
(1)
22. Function of adjustment [07]

The operator can adjust various items of the
machine on the monitor panel.
1) Selecting menu
select “07 Adjustment” and press the [ ]
switch.
Select a sub-menu to change its setting and
No. Sub-menu of adjustment

00 Return (Finish adjustment)
01 Pump absorption torque
Adjustment of oil flow for attachment in
02
compound operation
3) Function of pump absorption torque

The operator can adjust the pump absorp-
tion torque within the ranges shown in the
following table.
Adjustment Adjustment Adjustment Adjustment
value torque value torque
220 +8.0 kgm 225 –2.0 kgm
221 +6.0 kgm 226 –4.0 kgm
222 +4.0 kgm 227 –6.0 kgm
223 +2.0 kgm 228 –8.0 kgm
224 0.0 kgm
4) Function of adjustment of oil flow for attach-

ment in compound operation
The operator can adjust the oil flow for the
attachment in compound operation within
the ranges shown in the following table.
Adjustment value Oil flow for attachment
370 0.5 times
371 0.7 times
372 1.0 times
373 0.4 times
PC400/450(LC)-7 20-177
(1)
23. Function of cylinder cut out mode operation

[09]
The operator can operate the machine in the
cylinder cut out mode with the monitor panel.
Cylinder cut out mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective cyl-
inders. This operation is used to find out a cylin-
der which does not output power normally (or,
combustion in it is abnormal).
1) Selecting menu
select “09 Cylinder cut out mode operation”
and press the [ ] switch.
2) Setting cylinders to be disabled

Press switches [1] – [6] on the monitor panel
corresponding to the cylinder Nos. to be dis-
abled.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed white in a white frame,
the cylinder is disabled (If setting is
wrong, press the same switch again).
a Only one or more cylinders can be disa-
bled for the reduced cylinder mode oper-
ation.
3) Cancellation of disabled cylinders

Press switches [1] – [6] on the monitor panel
corresponding to the disabled cylinder Nos.
to cancel disabling of those cylinders.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed black in a black frame,
disabling of the cylinder is cancelled.
20-178 PC400/450(LC)-7
(1)
4) Function of holding engine speed

If the [ ] switch is pressed while the
reduced cylinder mode operation screen is
used, the engine speed is held and dis-
played on the lower line.
If the [ ] switch is pressed while the engine
speed is held, holding of the engine speed is
cancelled and the engine speed displayed
on the lower line goes off.
a If the holding function is used, the held
engine speed is displayed in ( ) on the
lower line and the current engine speed
is displayed on the upper line.
a The holding function can be used both in
and out of the cylinder cut out mode.
[Reference]: How to use holding function effec-

tively
The engine speed displayed by the holding
function is held on the screen until the holding
function is cancelled, regardless of setting and
cancellation of the cylinder cut out mode.
Accordingly, a defective cylinder can be found
out effectively according to the following proce-
dure.
(1) Run the engine normally (without disabling
any cylinder) and hold the engine speed.
(2) Disable a cylinder to be checked.
(3) Run the engine under the same condition as
the normal operation in step (1) and com-
pare the engine speed at this time with the
held engine speed.
(4) Cancel the cylinder cut out mode, regard-
less of the change of the engine speed.
(5) Repeat steps (2) – (4) to check the other
cylinders.
a If the engine speed does not lower at all or
lowers less when a cylinder is selected for
the cylinder cut out mode operation, com-
bustion in that cylinder must be abnormal.
PC400/450(LC)-7 20-179
(1)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Section to display Section to operate special Section to operate special function 2

special functions function 1 (Basic operation) (Selecting operation and special operation)
1. Display section 3. Caution buzzer stop switch 7. Working mode selector (UP) switch
2. Service meter 4. Auto-decelerator switch 8. Working mode selector (DOWN) switch
section 5. Setting switch (Black switch)
6. Travel speed shifting switch
PC400/450(LC)-7 20-179-2
(7)
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function
Ordinary functions (Operator menu) Special functions (Service menu)
<Operation of switch> O
1 Function of displaying service meter 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
2 Function of displaying user code 5 Function of selecting maintenance period [04]
6 Function of selecting default working mode [05]
7 Function of setting installation of attachment [16]
Special function of monitoring replacement

8
of engine oil
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
Display of operator menu
a Only outline of the operator menu is described in

this section. For details of each menu, see OP-
ERATION MANUAL or the volume of STRUC-
TURE AND FUNCTION.
1. Function of displaying service meter

While the machine is used normally, the monitor
panel displays the following information.
• Display section (1): Nothing is displayed
• Service meter section (2): Service meter
20-179-3 PC400/450(LC)-7
(7)
2. Function of displaying user code

If the machine has any trouble, the correspond-
ing user code is displayed automatically in dis-
play section (1) and the caution buzzer is turned
ON to urge the operator to take a proper rem-
edy, depending on the degree of the trouble.
a Service meter section (2) continues display-
ing the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the service code with the "Function of
displaying service code [01]" in the service
menu.
<Reference>
A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
a User codes and remedies shown to operator
User Caution
Error mode Remedy (shown to operator)
code buzzer
If the emergency pump drive switch is set in the upper position,
Error in pump
E02 the machine can operate normally. Have the machine inspected q
control system
immediately, however.
Set the swing holding brake release switch in the upper position
to release the brake. When applying the swing brake, operate
Error in swing
E03 the swing lock switch manually. The brake may not be released, q
brake system
depending on the cause of the failure. In this case, have the
machine inspected immediately.
Error in engine controller
power supply
E10 Abnormality in engine con- Have the machine inspected immediately. q
troller drive system circuit
(Engine is stopped)
Error in engine controller
system Move the machine to safe place and have it inspected immedi-
E11 q
(Engine output is reduced ately.
for protection)
Move the machine to safe place and have it inspected immedi-
E14 Error in throttle system q
ately.
Error in engine sensor
Have the machine inspected, although it can be operated nor-
E15 (coolant temperature, fuel q
mally.
temperature, oil pressure)
Move the machine to safe place and have it inspected immedi-
E0E Error in network q
ately.
PC400/450(LC)-7 20-179-4
(7)
Operation and display of service menu
How to select service menu

a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3. Function of displaying service code [01]
4. Monitoring function [02]
5. Function of selecting maintenance period
[04]
6. Function of selecting default working
mode [05]
7. Function of setting installation of attach-
ment [16]
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
2) Displaying display section and service meter

section
If the switches are operated as shown above,
the first menu No. [01] (Monitoring function) is
displayed in service meter section (2).
a Nothing is displayed in display section (1).
3) Selecting menu
operate working mode selector switches (7) and
(8) to select a menu you will use.
• UP switch (7): Increase Menu No.
• DOWN switch (8): Decrease Menu No.
Menu Service menu

No. (Excluding special functions)
01 Function of displaying error code
02 Monitoring function
04 Function of selecting maintenance period
05 Function of selecting default working mode
16 Function of setting installation of attachment
4) Executing menu
Select a menu you will use and press set switch
(5), and the menu is executed.
5) Finishing service menu

hold auto decelerator switch (4) for 2.5 seconds
(similarly to the selecting operation).
a The service menu is finished and the ordi-
nary screen appears.
a The service menu can be also finished by
turning the starting switch OFF while the
service menu is selected. (In this case, the
ordinary screen appears when the starting
switch is turned ON again.)
20-179-5 PC400/450(LC)-7
(7)
a To use the following special function, you must

operate the switches differently from the above.
See details of this function "8. Special function
of monitoring replacement of engine oil".
3. Function of displaying service code [01]

With this function, you can check the service
code of a trouble which is occurring at present
or has occurred in the past.
1) Selecting and executing function

i) Select menu No. [01] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Information displayed in display section and

service meter section 1 (When service code
is recorded)
If a service code is recorded, the following
information is displayed in display section
(1) and service meter section (2).
(a): Service code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occur-
ring at present
a Mark [E] to indicate that a trouble is oc-
curring at present indicates that the serv-
ice code is being detected now. It is not
displayed if the trouble has been re-
paired or the service code is not detect-
ed.
a For the service codes which the monitor
panel and engine throttle and pump con-
troller can detect, see the "Service
codes table".

service meter section 2 (When service code
is not recorded)
If a service code is not recorded, display
section (1) and service meter section (2)
display as shown in the figure.
4) Number of recorded service codes and dis-

play order of them
This function can record up to 20 service
codes, which are displayed in order from the
latest one.
a If a new trouble occurs while 20 service
codes are recorded, the oldest service
code is deleted and the service code of
the new trouble is recorded.
PC400/450(LC)-7 20-179-6
(7)
5) Change of displayed service codes

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to change the displayed service
codes.
• UP switch (7):
Next service code appears.
• DOWN switch (8):
Previous service code appears.
6) How to delete service code

i) While holding caution buzzer stop
switch (3), turn the starting switch OFF
and keep holding caution buzzer stop
switch (3).
ii) Under the above condition, turn the
starting switch ON again and hold cau-
tion buzzer stop switch (3) for 5 sec-
onds.
a A service code having the mark [E] is not
deleted.
20-179-7 PC400/450(LC)-7
(7)
Service codes table

User code Service code Trouble
— E112 Short circuit in wiper motor drive forward system
— E113 Short circuit in wiper motor drive reverse system
— E114 Short circuit in windshield washer drive system
— E115 Trouble in operation of windshield wiper
— E116 Trouble in storage of windshield wiper
— E117 Abnormality in engine controller S-NET
— E118 Abnormality in pump controller S-NET
E0E E128 Abnormality in communication (monitor)
— E201 Short circuit in travel junction solenoid
E03 E203 Short circuit in swing holding brake solenoid
— E204 Short circuit in merge-divider solenoid
— E205 Short circuit in 2-stage relief solenoid
— E206 Short circuit in travel speed shifting solenoid
— E211 Disconnection in travel junction solenoid
E03 E213 Disconnection in swing holding brake solenoid
— E214 Disconnection in merge-divider solenoid
— E215 Disconnection in 2-stage relief solenoid
— E216 Disconnection in travel speed shifting solenoid
— E217 Abnormality in input model code
— E218 Disconnection in S-NET signal line
— E222 Short circuit in LS-EPC solenoid
— E223 Disconnection in LS-EPC solenoid
— E224 Abnormality in F pump pressure sensor
— E225 Abnormality in R pump pressure sensor
— E226 Abnormality in pressure sensor power supply
— E227 Abnormality in engine speed sensor
— E228 Short circuit in ATT return selector relay
E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
— E238 Disconnection in ATT return selector relay
— E245 Short circuit in ATT flow adjustment EPC
— E246 Disconnection in ATT flow adjustment EPC
— E247 Abnormality in arm IN PPC pressure sensor
— E248 Abnormality in bucket CURL PPC pressure sensor
— E251 Abnormality in overload sensor
E0E E257 Abnormality in communication (pump)
— E315 Short circuit in battery relay output line
E11 E91B Abnormality in engine Ne speed sensor system
E11 E91C Abnormality in engine G speed sensor system
E11 E920 Abnormality in model selection system
E11 E921 Abnormality in model checking
E14 E931 Abnormality in fuel control dial system
E15 E934 Abnormality in coolant high temperature sensor
E15 E936 Abnormality in engine oil pressure switch system
PC400/450(LC)-7 20-179-8
(7)
User code Service code Trouble

E11 E93C Abnormality in boost pressure sensor system
E15 E93D Abnormality in fuel temperature sensor system
E0E E953 Abnormality in communication (engine)
— E954 Short circuit in starting switch C terminal system
E0E E955 Abnormality in network system
E10 E956 Abnormality in power supply system 1
E15 E957 Abnormality in power supply system 2
— E95A Abnormality in Q-adjustment switch signal
E15 E96A Abnormality in coolant low temperature sensor system
E11 E970 Overcurrent in fuel supply pump PCV1 system
E11 E971 Overcurrent in fuel supply pump PCV2 system
E11 E974 Disconnection in fuel supply pump PCV1 system
E11 E975 Disconnection in fuel supply pump PCV2 system
E11 E977 Abnormality in common rail fuel pressure sensor system
E11 E979 Abnormality in common rail fuel high pressure 1
E11 E97A Abnormality in common rail fuel high pressure 2
E15 E97B No-pressure feed by supply pump 1
E11 E97C No-pressure feed by supply pump 2
E11 E97D Abnormality in common rail fuel pressure
E11 E980 Abnormality in controller
E11 E981 Disconnection in fuel injector 1 system
E11 E98A Short circuit in fuel injector 1 – 3 systems
E11 E98B Short circuit in fuel injector 4 – 6 systems
E22 E922 Out of engine high idle standard
a "E" at the head of each service code indicates the following condition.
• With E: The trouble has not been repaired.
• Without E: The trouble has been repaired.
20-179-9 PC400/450(LC)-7
(7)
4. Monitoring function [02]

With this function, you can monitor the revolu-
tion speed, oil pressure, current, voltage, input
condition, output condition, etc. in real time by
the signals from the sensors, switches, and
solenoids installed to various parts of the
machine.

tion mode.
function.
2) Selecting and executing monitoring code

While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to select a monitoring code dis-
played in service meter section (1).
• UP switch (7): Increase code No.
• DOWN switch (8): Decrease code No.
a This function displays monitoring code
[00200] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".

service meter section 1 (When numeral
code is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is dis-
played)

service meter section 2 (When 6-bit code is
displayed)
If a 6-bit monitoring code is selected, the fol-
lowing information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (6 pieces of
information are displayed in bits)
a In the 6-bit display mode, only the top
and bottom of the 7-segments mark are
used to display. "Solid black" indicates
the ON state, and "white on black back-
ground" indicates the OFF state.
a For the No. of each bit, see the "Monitor-
ing codes table" and the drawing at-
tached to it.
PC400/450(LC)-7 20-179-10
(7)
Monitoring codes table
Code Monitoring item Unit Remarks
00200 Controller model code Numeral

00201 Controller model code Numeral
01002 Engine speed rpm
01601 2nd throttle command rpm
01100 F pump pressure kg/cm2
01101 R pump pressure kg/cm2
07200 Arm IN PPC pressure kg/cm2
07300 Bucket curl PPC pressure kg/cm2
04102 Engine coolant temperature (high) °C
14200 Fuel temperature °C
04401 Hydraulic oil temperature °C
01300 PC-EPC solenoid current mA
01500 LS-EPC solenoid current mA
01700 Service solenoid current mA
03200 Power supply voltage V
03500 Battery relay output voltage V
04300 Charge voltage V
01006 Engine speed rpm
04107 Engine coolant temperature (low) °C
36400 Common rail fuel pressure kg/cm2
36500 Boost pressure kg/cm2
36700 Converted torque %
03000 Fuel control dial voltage V
04200 Fuel sensor voltage V
04106 Engine coolant temperature sensor voltage high V
04105 Engine coolant temperature sensor voltage low V
14201 Fuel temperature sensor voltage V
36501 Boost pressure sensor voltage V
36401 Common rail pressure sensor voltage V
17200 PCV valve closing timing CA
17300 Engine control mode Numeral
31701 Throttle angle %
36100 Fuel injection rate command mm3/st
36200 Common rail pressure command kg/cm2
36300 Fuel injection timing command CA
20-179-11 PC400/450(LC)-7
(7)
a Swing (6 bit)
b Travel (6 bit)
c Boom LOWER (6 bit)
01900 Pressure switch 1
d Boom RAISE (6 bit)
e Arm IN (6 bit)
f Arm OUT (6 bit)
a Bucket CURL (6 bit)
b Bucket DUMP (6 bit)
01901 Pressure switch 2
c Service (6 bit)
d Travel differential pressure (6 bit)
a Travel junction (6 bit)
b Swing holding brake (6 bit)
02300 Solenoid 1 c Pump merge-divider (6 bit)
d 2-stage relief (6 bit)
e Travel speed shifting (6 bit)
02301 Solenoid 2 ATT return selection (6 bit)
a Knob switch (6 bit)
02200 Switch input 1 b Swing brake release switch (6 bit)
c Swing holding brake switch (6 bit)
a Model selection 1 (6 bit)
b Model selection 2 (6 bit)
02201 Switch input 2 c Model selection 3 (6 bit)
d Model selection 4 (6 bit)
e Model selection 5 (6 bit)
02202 Switch input 3 Key switch (ACC) (6 bit)
03700 Controller output 1 Battery relay drive (6 bit)
a Key switch (6 bit)
b Start (6 bit)
04500 Monitor input 1 c Preheating (6 bit)
d Light (6 bit)
e Radiator coolant level (6 bit)
a Air cleaner (6 bit)
04501 Monitor input 2 b Engine oil level (6 bit)
c Charge voltage (6 bit)
PC400/450(LC)-7 20-179-12
(7)
a Swing holding brake switch (6 bit)

b Buzzer cancel switch (6 bit)
04502 Monitor input 3 c Window limit switch (6 bit)
d W limit switch (6 bit)
e P limit switch (6 bit)
a Key switch (C) (6 bit)
b Engine oil pressure low (6 bit)
c Engine oil pressure high (6 bit)
17400 Engine controller input state
d Model selection 1 (6 bit)
e Model selection 2 (6 bit)
f Model selection 3 (6 bit)
Numeral and
36800 Right Q-adjustment switch (ROT-SW1)
alphabet
Numeral and
36801 Left Q-adjustment switch (ROT-SW2)
alphabet
a Pump controller (6 bit)
05100 S-NET connection state
b Engine controller (6 bit)
20200 Program version (monitor) Numeral
20212 Program version (pump controller) Numeral
20209 Program version (engine controller) Numeral
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
Display of numeral code Display of 6-bit code
20-179-13 PC400/450(LC)-7
(7)
5. Function of selecting maintenance period [04]

With this function, you can adjust the mainte-
nance period of the engine oil for the function of
the engine oil replacement monitor.

tion mode.
function.
2) Selecting maintenance period

The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a mainte-
nance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
Display mode/
Display
Maintenance period
0 Maintenance function is reset.
125 125-hour interval
d Demonstration mode
3) Settling maintenance period

The display or maintenance period
becomes effective when it is selected.
Accordingly, perform the ordinary finishing
operation.
<Special functions of engine oil replacement

monitor>
a For the method of displaying the engine oil
replacement monitor, method of checking
the elapsed time after replacement of engine
oil, method of clearing the elapsed time, and
method of displaying demonstration mode,
see "8. Special functions of engine oil re-
placement monitor".
PC400/450(LC)-7 20-179-14
(7)
6. Function of selecting default working mode [05]

With this function, you can freely select the
working mode which is set automatically when
the starting switch is turned ON (When the
machine is delivered, mode A is set).

tion mode.
function.
2) Selecting default working mode

The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
• UP switch (7): Next mode is displayed.
• DOWN switch (8): Previous mode is dis-
played.
a Nothing is displayed in display section
(1).
a The working mode changes in the fol-
lowing order: A o E o B
3) Settling default working mode

Press set switch (5) to settle the selected
working mode.
20-179-15 PC400/450(LC)-7
(7)
7. Function of setting installation of attachment [16]

With this function, you can set installation of
attachment.
a When an attachment is installed, if IN-
STALLED is not set with this function, the B-
mode function (automatic single/double op-
eration selecting function) cannot be used.

tion mode.
function.
a While this function is executed, [16SET]
is displayed in the service meter section
(2) and [0] or [1] is displayed in display
section (1).
2) Selecting installation of attachment

i) The current setting is displayed in serv-
ice meter section (1). Check the actual
installation of attachment and setting.
• [0]: Attachment is not installed.
• [1]: Attachment is installed.
ii) While holding caution buzzer stop
switch (3), operate working mode selec-
tor switches (7) and (8) to select [0] or
[1].
• UP switch (7): [1] is selected.
• DOWN switch (8): [0] is selected.
3) Settling installation of attachment

Press set switch (5) to settle the selected
setting of installation of attachment.
PC400/450(LC)-7 20-179-16
(7)
8. Special functions of engine oil replacement monitor

1) Ordinary display of engine oil replacement
monitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights
up and display the elapsed time in service
meter section (2) for 20 seconds each time
the starting switch is turned ON.
2) Checking elapsed time

To check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).
3) Clearing elapsed time

To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed in serv-
ice meter section (2).
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hours.
4) Function of demonstration mode

If the demonstration mode is selected, you
can perform demonstration of the oil mainte-
nance function when teaching the operation
to a customer.
The functions and display of the demonstra-
tion mode are as follows.
i) The internally set interval is recognized
as 250 hours and the elapsed time is
recognized as 240 hours.
ii) When the starting switch is turned ON
after the demonstration mode is set, the
ordinary display is repeated up to 3
times (number of the times of turning
the starting switch ON).
iii) After the demonstration is finished,
resetting of maintenance setting [0] is
recognized.
a When the demonstration is repeated 3
times, resetting of maintenance setting
is recognized. If setting is necessary at
this time, see "Function of selecting
maintenance period".
20-179-17 PC400/450(LC)-7
(7)
9. Function of cylinder cut out operation

1) How to "Cylinder cut out operation" to enter
i) Set the 2 stage selection mode (keep
the pushing buzzer stop switch and the
setting switch for 2.5 seconds) display-
ing 2.2.
ii) Push the setting switch.
iii) The same operation as i) is done when
coming off the mode.
2) Display method
i) Display engine speed in part (A) of
7segLED. (symbol is x 10 rpm) Ex). It is
displayed 1520 rpm, when it is 152.
State of cylinder cut out of each cylinder
is displayed in part (B) in 7segLED.
When cylinder No. is displayed, it shows
that cylinder cut out command has not
come out.
When the upper part of 7segLED lights,
it shows that cylinder cut out command
has come out from the monitor.
When the lower part of 7segLED lights,
it shows that cylinder cut out command
has come out from engine controller.
3) Operate method
i) 7segLED of (B) displays number (1-6)
of each cylinder in cylinder cut out oper-
ate mode. (Part (A) always displays
engine speed.)
The number of the cylinder that has
been selected now (Or, 7segLED that is
displayed the number) blink.
The cylinder is selected by
• Buzzer stop switch + working mode
selector (UP) switch
• Buzzer stop switch + working mode
selector (DOWN) switch
a When you select 3rd cylinder
ii) Select the number of the cylinder that

wants to do "cylinder cut out", and push
the buzzer stop switch + the setting
switch once when cylinder cut out com-
mand comes out from the monitor.
When cylinder cut out command came
from the monitor, the upper part of
7segLED lights.
PC400/450(LC)-7 20-179-18
(9)
iii) When cylinder cut out command comes

from the engine controller to the cylinder,
the lower part of the 7segLED lights.
iv) When you want also to give cylinder cut

out command similarly to other cylinder
Select the cylinder with buzzer stop
switch + working mode selector (UP)
switch or buzzer stop switch + working
mode selector (DOWN) switch and do a
similar operation.
a When you select 5th cylinder
v) When release the cylinder cut out com-

mand, the cylinder that wants to release
it is selected by the buzzer stop switch +
the working mode selector (UP) switch or
the buzzer stop switch + the working
mode selector (DOWN) switch and push
the buzzer stop switch + the setting
switch once.
When release the cylinder cut out
command, turn off the upper part of
7segLED.
vi) When release the cylinder cut out com-

mand from engine controller, turn off the
lower part.
20-179-19 PC400/450(LC)-7
(9)
vii) When both segments are turned off, the

number of the cylinder is displayed.
PC400/450(LC)-7 20-179-20
(7)
TESTING AND ADJUSTING HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
k The engine controller has a high-voltage circuit

(110 – 130 V) to drive the fuel injector. This cir-
cuit is connected to the wiring harness and con-
nectors between the engine controller and fuel
injector.
a Normally, the engine controller outputs the high
voltage to the fuel injector only while the engine
is running and stops outputting if the engine
stops.
k If you touch the high-voltage circuit directly, you
may get an electric shock. To avoid this, ob-
serve the following precautions.
1. The following connectors are used in the high-

voltage circuit.
• Engine controller connector: CB3
• Junction connector: ER03
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to turn
the starting switch OFF.
3. If a T-adapter is inserted in or connected to a

connector related to the high-voltage circuit for
troubleshooting, do not start the engine.
a You may turn the starting switch to the OFF
or ON position, but must not turn it to the
START position.
20-180 PC400/450(LC)-7
(1)
PREPARATION WORK FOR TROUBLESHOOTING FOR
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL

EQUIPMENT SYSTEM
a When carrying out troubleshooting for an elec- 2. Engine controller
tric circuit related to the monitor panel, engine 1) Open the right side cover and remove radia-
controller, or pump controller, expose the related tor sub tank (3) and bracket together.
connectors according to the following proce-
dure.
1. Monitor panel
1) Remove cover (1).
a The cover is fixed with the upper and
lower 2 clips. You can remove the cover
by pulling it up.
a If the sunlight sensor for the air condi-
tioner is installed, disconnect connector
P15 on the back side of the cover.
2) Remove the 4 mounting bolts and pull out

engine controller (4).
3) Insert or connect T-adapters in or to con-
nectors CB1, CB2, and CB3 of the engine
controller.
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
a When connecting the connectors again,
tighten their screws to the specified
3 Screw: 2.82 Nm {0.288 kgm}

torque.
2) Remove the 3 mounting screws and discon-
nect monitor panel (2) from the mount.
a Take care not to drop the mounting
screws in the console.
3) Insert or connect T-adapters in or to con-
nectors P01, P02, P70 of the monitor panel.
PC400/450(LC)-7 20-181
(1)
PREPARATION WORK FOR TROUBLESHOOTING FOR
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT SYSTEM
3. Pump controller
a The pump controller is installed inside the cover
at the rear of the operator’s seat.
1) Remove the 3 mounting bolts and cover (5).
2) Insert or connect T-adapters in or to connectors

C01, C02, and C03 of the pump controller.
a Since the connectors are secured with
screws, loosen those screws before discon-
necting.
a When connecting the connectors again,
3 Screw: 2.82 Nm {0.288 kgm}

tighten their screws to the specified torque.
20-182 PC400/450(LC)-7
(1)
PM-CLINIC SERVICE
PC400/450(LC)-7 20-183
(1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to engine)
20-184 PC400/450(LC)-7
(1)
MEASURING PROCEDURES
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
PC400/450(LC)-7 20-185
(1)
20-186 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-187
(1)
Pm-CLINIC SERVICE PC400 (LC), 450 (LC)-7
Visual check of welded structures
a If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
T Left T Right T Left T Right T Left T Right
2. Arm foot 5. Boom cylinder bracket
T Left T Right T End plate T Left T Right Track frame
3. Arm top boss 6. Arm cylinder bracket 10. Circle bracket
T Left T Right T Left T Right T Front T Rear
7. Boom lower plate T Left T Right
T Left T Right
8. Boom foot
T Left T Right
20-188 PC400/450(LC)-7
(1)
UNDERCARRIAGE INSPECTION
(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model PC400/450-7 Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry DRY
Soil condition Dealer Shoe width (mm)
Working condition nspector Shoe type TRIPLE
Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type NORMAL
New 100% Measured Wear SMR Hours on Comments/Observation
Wear mm % New Rebuilt Parts:
LH 915.6 927.6
R
RH 915.6 927.6
LH 228.90 231.90
M
RH 228.90 231.90
LH 129.0 119.0
RH 129.0 119.0
New Turned
LH 71.5 66.5
New Turned
RH 71.5 66.5
LH 37.0 22.0
RH 37.0 22.0
LH 148.0 134.0
Front
RH 148.0 134.0
LH 148.0 134.0
Rear
RH 148.0 134.0
LH 22.0 28.0
Front
RH 22.0 28.0
LH 22.0 28.0
Rear
RH 22.0 28.0
1 LH 200.0 188.0
2 LH 200.0 188.0
3 LH 200.0 188.0
4 LH 200.0 188.0
5 LH 200.0 188.0
6 LH 200.0 188.0
7 LH 200.0 188.0
8 LH 200.0 188.0
9 LH 200.0 188.0
10 LH 200.0 188.0
1 RH 200.0 188.0
2 RH 200.0 188.0
3 RH 200.0 188.0
4 RH 200.0 188.0
5 RH 200.0 188.0
6 RH 200.0 188.0
7 RH 200.0 188.0
8 RH 200.0 188.0
9 RH 200.0 188.0
1.3 10 RH 200.0 188.0
LH 0.0 6.0
RH 0.0 6.0
Remarks:
PC400/450(LC)-7 20-189
(1)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM.................................................................................................................................... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM”
AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED .................................................. 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601
TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701
PC400/450(LC)-7 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC400/450(LC)-7
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC400/450(LC)-7 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on “Handling electric equipment“ and “Handling hydraulic
equipment” (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC400/450(LC)-7
(1)
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 solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC400/450(LC)-7 20-205
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips

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

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC400/450(LC)-7
(1)
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC400/450(LC)-7 20-207
(1)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC400/450(LC)-7
(1)
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
PC400/450(LC)-7 20-209
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. 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 on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 PC400/450(LC)-7
(1)
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
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 ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC400/450(LC)-7 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
mechanical
equipment
Hydraulic,
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace

2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention to — Disconnect
water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-212 PC400/450(LC)-7
(1)
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
Code display
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC400/450(LC)-7 20-213
(1)
Phenomena considered to be failures and troubleshooting Nos.
Troubleshooting
No. Phenomena considered to be failures Display of
E-mode H-mode S-mode
code
Possible faults related to user code, error code, or failure code
1 User code is displayed on monitor panel
Accord-
When failure history is checked, error code is displayed in electrical
2 ing to
system
displayed
When failure history is checked, error code is displayed in mechani- code
3
cal system
Possible faults related to engine
4 Engine does not start easily (It always takes time to start) S-1
5 Engine does not crank E-1 S-2 a)
Engine cranks but exhaust smoke
6 S-2 b)
Engine does not start does not come out
Exhaust smoke comes out but engine
7 S-2 c)
does not start
8 Engine speed does not rise sharply (Follow-up performance is low) S-3
9 Engine stops during operation S-4
10 Engine rotation is abnormal (Engine hunts) S-5
11 Output is insufficient (Power is low) S-6
12 Exhaust gas color is bad (Incomplete combustion) S-7
13 Oil is consumed much or exhaust gas color is bad S-8
14 Oil becomes dirty quickly S-9
15 Fuel is consumed much S-10
16 Coolant contains oil (or it blows back or reduces) S-11
17 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
18 Oil level rises (Water or fuel is mixed in oil) S-13
19 Water temperature rises too high (Overheating) S-14
20 Abnormal sound comes out S-15
21 Vibration is excessive S-16
22 Engine is not preheated normally E-2
23 Automatic warm-up function does not work E-3
24 Automatic decelerator does not work E-4 H-5
Possible faults related to work equipment, swing, and travel
25 Speed or power of whole work equipment, travel, and swing is low H-1 S-6
26 Engine speed lowers extremely or engine stalls H-2 S-4
27 Work equipment, travel, and swing systems do not work E-5 H-3
28 Abnormal sound comes out from around hydraulic pump H-4
29 Fine control performance or response is low H-6
20-214 PC400/450(LC)-7
(1)
Troubleshooting
code
Possible faults related to work equipment
30 Speed or power of boom is low H-7
31 Speed or power of arm is low H-8
32 Speed or power of bucket is low H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
When a work equipment device is relieved singly, other work equip-
36 H-13
ment device moves
37 One-touch power maximizing function does not work E-6 H-14
38 Machine push-up function does not work normally E-7 H-15
39 Attachment circuit is not selected (when attachment is installed) E-8 H-30
Oil flow in attachment circuit cannot be adjusted (when attachment is
40 H-31
installed)
Possible faults related to compound operation
In compound operation of work equipment, speed of part loaded
41 H-16
more is low
When machine swings and raises boom simultaneously, boom rising
42 H-17
speed is low
When machine swings and travels simultaneously, travel speed low-
43 H-18
ers largely
Possible faults related to travel
44 Machine deviates during travel H-19
45 Travel speed is low H-20
46 Machine is not steered well or steering power is low H-21
47 Travel speed does not change or it is lower or higher than set speed H-22
48 Travel motor does not work (only 1 side) H-23
49 Travel alarm does not sound or does not stop sounding E-31
Possible faults related to swing
47 Machine does not swing H-24
48 Swing acceleration or swing speed is low H-25
50 Upper structure overruns remarkably when it stops swinging H-26
51 Large shock is made when upper structure stops swinging H-27
52 Large sound is made when upper structure stops swinging H-28
53 Hydraulic drift of swing is large H-29
Possible faults related to monitor panel (Operator menu: Ordinary screen)
54 No items are displayed on monitor panel E-9
55 Some items are not displayed on monitor panel E-10
56 Items displayed on monitor panel are not matched to machine model E-11
57 Fuel level monitor lights red while engine is running E-12
PC400/450(LC)-7 20-215
(1)
Troubleshooting
code
58 Engine coolant temperature gauge does not indicate normally E-13
59 Hydraulic oil temperature gauge does not indicate normally E-14
60 Fuel level gauge does not indicate normally E-15
61 Swing lock monitor does not indicate normally E-16
62 When monitor switches are operated, no items are displayed E-17
63 Windshield wiper or windshield washer does not operate E-18
64 Alarm buzzer cannot be cancelled E-19
Possible faults related to monitor panel (Service menu: Special function screen)
65 Monitoring function does not indicate “Boom RAISE” normally. E-20
66 Monitoring function does not indicate “Boom LOWER” normally. E-21
67 Monitoring function does not indicate “Arm IN” normally. E-22
68 Monitoring function does not indicate “Arm OUT” normally. E-23
69 Monitoring function does not indicate “Bucket CURL” normally. E-24
70 Monitoring function does not indicate “Bucket DUMP” normally. E-25
71 Monitoring function does not indicate “Swing” normally. E-26
72 Monitoring function does not indicate “Travel” normally. E-27
Monitoring function does not indicate “Travel differential pressure”
73 E-28
normally.
74 Monitoring function does not indicate “Service” normally. E-29
Other failure
Air conditioner does not operate
75 E-31
(Troubleshooting for air conditioner system)
20-216 PC400/450(LC)-7
(1)
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
TROUBLESHOOTING CIRCUIT DIAGRAM OF EACH SYSTEM

CIRCUIT DIAGRAM OF EACH SYSTEM
Connectors list
a The address of each connector roughly shows the place of the connector in the connectors stereogram and
the circuit diagram of each system.
Address
Connector No. of
Type Name of device Stereo- M E P
No. pins
gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 D-7 G-7
A02 X 4 Intermediate connector T-1 H-6 G-7
A03 DT 12 Intermediate connector N-2 H-6 D-7 G-7
A04 SWP 6 Intermediate connector O-1 G-6
A05 SWP 14 Intermediate connector T-1 H-5 G-6
A06 SWP 14 Intermediate connector O-1 H-5 G-5
A07 SWP 16 Intermediate connector S-1 A-4 D-7 G-5
A09 SWP 8 Intermediate connector N-2 G-5
A10 Terminal 1 Revolving frame grounding H-2 I-1 F-1 J-8
A11 Terminal 1 Revolving frame grounding I-2 F-1
A12 Terminal 1 Revolving frame grounding I-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-8
A14 Terminal 1 Revolving frame grounding F-1 I-1 J-8
A15 Terminal 1 Revolving frame grounding J-3 I-1 J-8
A16 Terminal 1 Revolving frame grounding J-3 I-1 K-8
A20 Terminal 1 Battery relay (Terminal E) D-1 L-5 K-9
A21 Terminal 1 Battery relay (Terminal BR) D-2 J-6 K-9
A22 Terminal 1 Battery relay (Terminal N) F-2 J-5 D-8 K-9
A23 Terminal 1 Battery relay (Terminal B) F-2 J-6 K-9
A31 D 2 Air cleaner clogging sensor H-9 K-4
A33 X 2 Radiator water level sensor H-9 K-5
A34 L 2 Fusible link (65 A) D-2 K-6 K-9
A35 M 2 Fusible link (30 A) G-9 K-6 D-9 K-9
A40 Terminal 1 Horn (Low tone) G-9
A41 Terminal 1 Horn (High tone) G-9
A42 M 1 Intermediate connector H-9 J-7
A43 D 2 Travel alarm J-3 K-5
A44 M 1 Right headlamp D-5 K-7
A50 KES0 2 Windshield washer motor (Tank) L-5 K-5
A51 D 3 F pump oil pressure sensor L-8 L-5
A52 D 3 R pump oil pressure sensor L-7 L-5
A60 X 1 Fuel level sensor G-9 K-4
A61 D 2 Hydraulic oil temperature sensor L-5 K-5
Boom cylinder bottom pressure sensor for overload
A70 D 3 H-1 K-3
alarm
A73 D 2 Fuel priming pump G-9
A80 DT 8 Intermediate connector S-1 H-3 D-6 G-4
AL/B Terminal 1 Alternator B terminal AE-6
AL/E Terminal 1 Alternator E terminal AE-6
AL/R Terminal 1 Alternator R terminal AE-6
C01 DRC 24 Pump controller U-9 A-3 A-8 A-8
C02 DRC 40 Pump controller U-9 A-3 A-8 A-7
C03 DRC 40 Pump controller W-9 A-2 A-6
C09 S 8 Model selection connector (Pump controller) W-9 B-1
CB1 DRC 24 Pump controller I-9 K-1 A-6 L-8
PC400/450(LC)-7 20-217
(4)
Address
Connector No. of
No. pins
CB2 DRC 40 Pump controller I-9 K-1 A-5 L-8
CB3 DRC 40 Pump controller J-9 A-3
CB5 DT 8 Model selection connector (Engine controller) J-9 A-7
CN1 DT 2 No. 1 fuel injector AI-2 K-3
CN2 DT 2 No. 2 fuel injector AI-3 K-2
CN3 DT 2 No. 3 fuel injector AJ-3 K-2
D01 SWP 8 Concentrated diode W-7 A-9 A-4
D02 SWP 8 Concentrated diode W-5 A-8 A-4
E06 M 3 Fuel control dial P-7 K-7
ENE DT 2 Engine speed sensor AJ-5
ER02 HD30 31 Intermediate connector AF-8 J-3 I-5 K-6
ER03 HD30 31 Intermediate connector AF-8 I-3
F02 M 2 Rotary lamp AA-9
FB1 — — Fuse box V-2 I-9 E-7 G-8
G YAZAKI 2 Engine G sensor AH-2 K-3
GND DT 2 Joint connector (with diode) AJ-6
GND2 Terminal 1 Engine grounding AJ-5
GND3 Terminal 1 Engine grounding AE-7
H08 M 8 Intermediate connector W-6 J-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector T-9 D-6 I-7 E-2
H11 S 16 Intermediate connector S-9 D-6 E-2
H12 S 12 Intermediate connector S-9 D-5 I-6 E-2
H15 S090 20 Intermediate connector O-7 C-2 I-7 A-2
HT/B Terminal 1 Heater relay B terminal AH-9
HT/S Terminal 1 Heater relay S terminal AJ-7
J01 J 20 Junction connector (Black) T-9 C-9 H-9 B-9
J02 J 20 Junction connector (Black) T-9 D-9 C-1
J03 J 20 Junction connector (Green) U-9 D-9 H-9 C-9
J04 J 20 Junction connector (Green) V-3 E-9 H-9 C-9
J05 J 20 Junction connector (Pink) V-3 E-9 D-9
J06 J 20 Junction connector (Orange) W-3 F-9 I-9 D-9
J07 J 20 Junction connector (Orange) W-5 F-9 I-9 D-9
J08 J 20 Junction connector (Pink) W-5 I-9 E-9
K19 M 2 Pump resistor (For driving pump in emergency) W-5 B-1
K30 DT 3 CAN terminal resistance K-9 A-2 A-9 A-9
K31 DT 3 CAN terminal resistance N-4 A-4 K-6 E-1
M07 M 3 Light switch P-8 C-1
M09 M 1 Working lamp (Right front) E-9 K-7
M13 M 2 Speaker (Right) AC-9
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch O-7
M23 Y090 2 One-touch power maximizing switch T-1 F-9
M26 S 12 Intermediate connector W-4
M27 YAZAKI 18 Air conditioner unit W-4
M29 040 20 Air conditioner control panel U-2
M30 040 16 Air conditioner control panel U-2
20-218 PC400/450(LC)-7
(4)
Address
Connector No. of
No. pins
M31 M 2 Optional power supply (2) W-7
M32 M 2 Optional power supply (1) W-6
M33 M 2 Optional power supply (3) V-9
M33 SUMITOMO 4 Air conditioner unit W-4
M34 X 1 Air conditioner compressor electromagnetic clutch I-9
M37 Terminal 1 Horn switch (High tone) H-1
M38 Terminal 1 Horn switch (Low tone) G-1
M38 M 2 Machine push-up switch Q-8 A-1
M40 M 2 Working lamp Z-8 K-8
M41 M 2 Working lamp (Additional) Y-7 K-8
M42 M 1 Intermediate connector H-9 J-7, K-7
M43 M 1 Working lamp (Rear) J-9 K-7
M45 D 12 Intermediate connector W-7
M46 X 4 RS232C junction connector V-9 A-4
M71 M 2 Room lamp AA-8
M72 M 4 DC/DC converter U-2
M73 M 2 Speaker (Left) AD-8
M79 M 2 12-V accessory outlet V-9
NE YAZAKI 2 Engine Ne sensor AJ-5 K-4
OL DT 2 Engine oil level sensor AJ-3 K-2
P01 070 12 Monitor panel N-6 A-7 K-7 E-1
P03 M 2 Buzzer cancel switch Q-8 D-1
P05 M 2 Rotary lamp switch U-2
P15 Y050 2 Air conditioner daylight sensor N-5
PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2 K-1
PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2 K-1
PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2 L-5
PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1 L-5
PFUEL AMP 3 Common rail pressure sensor AJ-4 K-5
PIM SUMITOMO 3 Boost pressure sensor AJ-8 K-5
R10 R 5 Light relay P-7 E-1
R11 R 5 Starting motor cutout relay (PPC lock) P-8 E-1
R13 R 5 Starting motor cutout relay (Personal code) Q-8 F-1
R20 R 5 ATT circuit selector relay W-7 E-9
R22 R 5 Power supply relay for engine controller W-6 G-9
R30 R 5 Air conditioner blower relay W-4
R31 R 5 Air conditioner compressor relay W-3
S01 D 4 Bucket CURL pressure sensor K-3 K-3
S02 X 2 Boom LOWER oil pressure switch L-2 K-2
S03 X 2 Swing RIGHT oil pressure switch L-2 K-2
S04 D 3 Arm IN pressure switch K-3 K-3
S05 X 2 Bucket DUMP oil pressure switch L-2 K-2
S06 X 2 Boom RAISE oil pressure switch L-2 K-2
S07 X 2 Swing LEFT oil pressure switch L-2 K-2
S08 X 2 Arm DUMP oil pressure switch L-1 K-2
S09 X 2 Service oil pressure switch (Intermediate connector) L-1 K-1
S10 X 2 Service front oil pressure switch K-1 K-1
S11 X 2 Service rear oil pressure switch L-1 K-1
S14 M 3 Safety lock lever switch S-1 K-9 E-9
PC400/450(LC)-7 20-219
(4)
Address
Connector No. of
No. pins
S21 Terminal 6 Emergency pump drive switch R-9 C-1
S22 Terminal 6 Swing holding brake release switch R-8 D-1
S25 S090 16 Intermediate connector R-9 C-2
S30 X 2 Travel oil pressure switch P-1 A-9
S31 X 2 Travel steering oil pressure switch P-1 A-9
ST DT 2 Starting motor AF-7 K-3 K-6
ST/B Terminal 1 Starting motor B terminal AF-7
T05 Terminal 1 Floor frame grounding V-3 J-8
T06 Terminal 1 Radio body grounding S-9
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Cab grounding K-8
THL DT 3 Spill fuel temperature sensor AJ-4 K-3
Engine water temperature sensor (High tempera-
TWH DT 2 AE-7 K-5
ture)
Engine water temperature sensor (Low tempera-
TWL DT 3 AG-8 K-5
ture)
V01 DT 2 PPC oil pressure lock solenoid valve J-3 K-5
V02 DT 2 Travel junction solenoid valve J-2 K-5
V03 D 2 Merge-divider solenoid valve J-2 K-4
V04 D 2 Travel speed solenoid valve J-2 K-4
V05 D 2 Swing holding brake solenoid valve J-2 K-4
V06 D 2 Machine push-up solenoid valve J-2 K-4
V08 D 2 2nd-stage relief solenoid valve J-1 K-4
V12 D 2 ATT return selector solenoid valve J-1 K-4
V21 D 2 PC-EPC solenoid valve L-6 L-7
V22 D 2 LS-EPC solenoid valve L-6 L-7
V30 X 2 ATT flow adjustment EPC solenoid valve P-1 F-1
W03 M 2 Rear limit switch (Window) AB-9 K-8
W04 M 6 Wiper motor Y-5 B-9
X05 M 4 Swing lock switch Q-8 D-2 A-1
20-220 PC400/450(LC)-7
(4)
Connector type Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
070 Product of Japan AMP 070 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki 090 type connector
YAZAKI Yazaki-made connector
SUMITOMO Product of Sumitomo Wiring Systems 6098 type connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
PC400/450(LC)-7 20-221
(1)
Connector Location Stereogram
20-222 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-223
(4)
20-224 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-225
(1)
20-226 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-227
(1)
Monitor Panel System Circuit Diagram (M Circuit)
20-228 PC400/450(LC)-7
(1)
a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging
system, light system, and communication network system from the general electric circuit diagram.
PC400/450(LC)-7 20-229
(1)
Engine Control System Circuit Diagram (E Ciruit)
20-230 PC400/450(LC)-7
(1)
a This circuit diagram is made by extracting the engine controller system from the general electric circuit dia-
gram.
PC400/450(LC)-7 20-231
(1)
Pump Controller System Circuit Diagram (P Circuit)
20-232 PC400/450(LC)-7
(4)
a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine
push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
PC400/450(LC)-7 20-233
(4)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-234 PC400/450(LC)-7
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC400/450(LC)-7 20-235
(1)
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-236 PC400/450(LC)-7
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
PC400/450(LC)-7 20-237
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-238 PC400/450(LC)-7
(1)
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC400/450(LC)-7 20-239
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-240 PC400/450(LC)-7
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC400/450(LC)-7 20-241
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-242 PC400/450(LC)-7
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
PC400/450(LC)-7 20-243
(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-244 PC400/450(LC)-7
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC400/450(LC)-7 20-245
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-246 PC400/450(LC)-7
(1)
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC400/450(LC)-7 20-247
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-248 PC400/450(LC)-7
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC400/450(LC)-7 20-249
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-250 PC400/450(LC)-7
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC400/450(LC)-7 20-251
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-252 PC400/450(LC)-7
(1)
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC400/450(LC)-7 20-253
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-254 PC400/450(LC)-7
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC400/450(LC)-7 20-255
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins
—
part name
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
20-256 PC400/450(LC)-7
(1)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
PC400/450(LC)-7 20-257
(1)
Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fus-
ible link to see if the power is supplied normally.
Type of
Fuse No. Fuse capacity Destination of powerDestination of power
power supply
Pump controller (Controller power supply)
Swing holding brake solenoid
1 10 A
(When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
Switch power supply 2 20 A Machine push-up solenoid
(Fusible link: A34) ATT return selector relay & solenoid
Starting motor cutout relay (For PPC lock)
3 10 A
PPC lock solenoid
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn
6 10 A (Spare)
7 10 A Rotary lamp
8 10 A Right front working lamp & boom working lamp
Switch power supply
(Fusible link: A34) One-touch power maximizing switch
9 10 A (Input to pump controller input)
Radio
10 10 A (Spare)
11 20 A Air conditioner unit
Monitor panel
12 20 A
Starting motor cutout relay (For personal code)
Switch power supply Light relay (For right front working lamp & boom working lamp)
13 20 A
(Fusible link: A34) Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
Travel alarm
15 10 A
Service power supply 2 (DC/DC converter)
16 10 A Radio (For backing up)
Constant 17 10 A Monitor panel (For backing up)
power supply 18 10 A Starting switch
(Fusible link: A35) 19 10 A Room lamp
20 10 A (Spare)
20-258 PC400/450(LC)-7
(1)
TROUBLESHOOTING WHEN ERROR CODE
“ELECTRICAL SYSTEM” AND FAILURE CODE
“MECHANICAL SYSTEM” ARE DISPLAYED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304

Error Code in Electrical System [E112]
(Short-circuiting in normal rotation system of windshield wiper motor drive)........................................ 20-306
(Short-circuiting in reverse rotation system of windshield wiper motor drive)....................................... 20-308
Error Code in Electrical System [E114] (Short-circuiting in window washer drive system) ......................... 20-310
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) ........................................... 20-312
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) ................................. 20-314
Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)............................................. 20-316
Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)........................................... 20-318
Error Code in Electrical System [E128] (Monitor Comm. Abnormality)....................................................... 20-320
Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) ............................ 20-322
Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) ........................ 20-324
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid).................................... 20-326
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) ................................... 20-327
Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) ........................ 20-328
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid).............................. 20-329
Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid).......................... 20-330
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)..................................... 20-332
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)..................................... 20-333
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid).......................... 20-334
Error Code in Electrical System [E217] (Abnormal input model code)........................................................ 20-336
Error Code in Electrical System [E218] (S-Net Comm. Disc.)..................................................................... 20-338
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) ........................................... 20-340
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) ................................ 20-341
Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) .................................................. 20-342
Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) .................................................. 20-344
Error Code in Electrical System [E226] (Press. Sensor Power Abnormality).............................................. 20-346
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) ........................................ 20-348
Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay).................. 20-349
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid) .......................................... 20-350
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)................................ 20-352
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay) ................... 20-354
Error Code in Electrical System [E245] (Short-circuiting in attachment oil flow rate adjusting EPC).......... 20-356
Error Code in Electrical System [E246] (Disconnection in attachment oil flow rate adjusting EPC) ........... 20-357
Error Code in Electrical System [E247] (Arm IN PPC pressure sensor abnormality) ................................. 20-358
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)....................... 20-360
Error Code in Electrical System [E257] (Pump Abnormality) ...................................................................... 20-362
Error Code in Electrical System [E315] (Battery Relay Drive S/C) ............................................................. 20-364
Error Code in Electrical System [E91B] (Engine Ne sensor problem) ........................................................ 20-366
Error Code in Electrical System [E91C] (Engine G sensor problem) .......................................................... 20-367
Error Code in Electrical System [E920] (Engine type selection error)......................................................... 20-368
Error Code in Electrical System [E921] (Engine type mismatch) ................................................................ 20-370
Error Code in Electrical System [E931] (Fuel dial sys. error)...................................................................... 20-372
Error Code in Electrical System [E934] (Engine coolant sensor Hi error)................................................... 20-374
PC400/450(LC)-7 20-301
(1)
TROUBLESHOOTING
Error Code in Electrical System [E936] (Engine oil press. sw. error) .......................................................... 20-376
Error Code in Electrical System [E93C] (Engine boost sensor error) ......................................................... 20-378
Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) .................................................. 20-380
Error Code in Electrical System [E953] (Engine Comm. Abnormality)........................................................ 20-382
Error Code in Electrical System [E954] (Short engine starter sw.).............................................................. 20-384
Error Code in Electrical System [E955] (Engine S-NET error) .................................................................... 20-386
Error Code in Electrical System [E956] (Engine power failure (1)) ............................................................. 20-388
Error Code in Electrical System [E957] (Engine power failure (2)) ............................................................. 20-390
Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error).................................................... 20-392
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error) .................................................. 20-394
Error Code in Electrical System [E970] (PCV1 over current) ...................................................................... 20-396
Error Code in Electrical System [E971] (PCV2 over current) ...................................................................... 20-397
Error Code in Electrical System [E974] (PCV1 line cut).............................................................................. 20-398
Error Code in Electrical System [E975] (PCV2 line cut).............................................................................. 20-399
Error Code in Electrical System [E977] (Rail press. sensor error) .............................................................. 20-400
Error Code in Electrical System [E979] (Rail press. high)........................................................................... 20-402
Error Code in Electrical System [E97A] (Rail press. abnormal) .................................................................. 20-402
Error Code in Electrical System [E97B] (Rail press. low)............................................................................ 20-403
Error Code in Electrical System [E97C] (Rail press. too low) ..................................................................... 20-405
Error Code in Electrical System [E97D] (Rail press. out of control) ............................................................ 20-405
Error Code in Electrical System [E980] (Eng. Controller Abnormality) ....................................................... 20-406
Error Code in Electrical System [E981] (Fuel Injector 1 Disc.).................................................................... 20-408
Error Code in Electrical System [E984] (Fuel Injector 4 Disc.).................................................................... 20- 411
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) ............................................................... 20-414
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) ............................................................... 20-416
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)........................... 20-418
Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) ............................ 20-418
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) ........................................................ 20-420
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) ....................................................... 20-420
Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)...................................................... 20-424
Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)........................................................ 20-426
Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat).................................................... 20-427
Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)....................................................... 20-428
Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)........................................................ 20-429
20-302 PC400/450(LC)-7
(1)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
User Code Error Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass “Good” or “No Good” judgement
over the presumed cause
1
• Reference for passing the above “Good” or “No Good” judgement
<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness
occurred.
2 • Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with
standard value in normalcy
the grounding circuit.

Presumed cause and
• Short-circuiting
A wiring harness that is not connected with a 24 V electric circuit has a contact
Cause that presumably
with the electric circuit.
triggered failure in
3
question (The assigned
<Precaution for Troubleshooting>
No. is for filing purpose
1) Connector No. display method and handling of T-adapter
only. It does not stand for
Insert or connect T-adapters in the following manner before starting
any priority)
troubleshooting unless otherwise instructed.
• If there is no indication of “male” or “female” in a specific connector No.,
4 disconnect the connector and insert the T-adapter into both male and female
sides.
• If there is an indication of “male” or “female” in a specific connector No.,
disconnect the connector and connect the T-adepter with only one side of either
“male” or “female”.
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring
harness.
20-304 PC400/450(LC)-7
(1)
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC400/450(LC)-7 20-305
(1)
TROUBLESHOOTING E112

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine
Relative
information

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Windshield wiper motor position for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between (3) and (1) Continued

Presumed cause and
Between (3) and grounding Above 1 Mz

Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) (9) and Resistance Above
circuit) W04 (male) (3) and grounding value 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between (9) and ground-
ing Below 3 V 20 – 30 V
ON
(at constant cycle)
20-306 PC400/450(LC)-7
(1)
Electric Circuit Diagram for Windshield Wiper Motor
PC400/450(LC)-7 20-307
(1)

(Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine
Relative
information

Windshield wiper motor position for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
or grounding fault) Between (1) and (3) Continued

Presumed cause and

harness position for the troubleshooting.
2
circuit) W04 (male) (1) and grounding value 1 Mz
P01 Windshield wiper switch Voltage
OFF Below 3 V
Between (10) and
grounding Below 3 V 20 – 30 V
ON
(at constant cycle)
20-308 PC400/450(LC)-7
(1)
Electric Circuit Diagram for Windshield Wiper Motor
PC400/450(LC)-7 20-309
(1)

(Short-circuiting in window washer drive system)
User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
Failure content
was switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
Relative
information

Window washer drive position for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z

Presumed cause and
Short-circuiting of wiring position for the troubleshooting.
harness Between wiring harness from P01 (female) (3) to J04 to
2
(Contact with 24 V A50 (female) (2) and grounding, or between wiring
circuit) Voltage Below 1 V
harness between P01 (female) (3) and D02 (female) (8)
and grounding
3 Monitor panel defective P01 Window washer switch Voltage
Between (3) and OFF 20 – 30 V
grounding ON Below 1 V
20-310 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Window Washer Motor
PC400/450(LC)-7 20-311
(1)
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)
User Code Error Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)

Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Below 1 z
range
Between (6) and (5)
Outside upper end of
Above 1 Mz
operation range
Presumed cause and
Disconnection of wiring position for the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 Resistance
2 Below 1 z
(Disconnection or faulty (male) (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 z
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
Between (5) and range
grounding Outside upper end of
20 – 30 V
operation range
20-312 PC400/450(LC)-7
(1)
Windshield Wiper Motor Electrical Circuit Diagram
PC400/450(LC)-7 20-313
(1)
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)
User Code Error Code Failure Code Failure Abnormal in retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor Input 3)

Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Below 1 z
Between (4) and (5)

Operation range Above 1 Mz
Presumed cause and
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between P01 (female) (12) and W04 Resistance
2 (Disconnection or Below 1 z
(male) (4) value
defective contact with
connector) Resistance
Between wiring harness W04 (male) (5) and grounding Below 1 z
value
position during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Between (12) and Retraction range Below 1V
grounding Operation range 20 – 30 V
20-314 PC400/450(LC)-7
(1)
Windshield Wiper Motor Electrical Circuit Diagram
PC400/450(LC)-7 20-315
(1)
Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)
User Code Error Code Failure Code Failure Eng. Controller S-NET Comm. Err.
— E117 DAC0KR phenomenon (Monitor panel system)
• The monitor panel detected communication failure in the S-NET communication circuit to the engine
Failure content
controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)

Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
1 (Disconnection or defec- Wiring harness between P02 (female) (9), (10) and CB2
tive contact with connec- Resistance
(female) (21), (31) or between P02 (female) (9), (10) Below 1 z
tor) value
and C02 (female) (21)
Grounding fault of wiring position during the troubleshooting.
harness Between wiring harness between P02 (female) (9), (10)
2
(Contact with grounding and CB2 (female) (21), (31) or between P02 (female) Resistance
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
Short-circuiting of wiring
3 harness Between wiring harness between P02 (female) (9), (10)
(Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) Voltage Below 1 V
(9), (10) and C02 (female) (21) and related circuits and
grounding
Engine controller position during the troubleshooting.
4
defective CB2 Voltage
Between (21), (31) and (11) 6–9V
P02 Voltage
Between (9), (10) and (20) 6–9V
20-316 PC400/450(LC)-7
(1)
Electrical circuit diagram related to S-NET communication
PC400/450(LC)-7 20-317
(1)
Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)
User Code Error Code Failure Code Failure Pump Controller S-NET Comm. Err.
— E118 DAB0KR phenomenon (Monitor panel system)
• The monitor panel detected communication failure in the S-NET communication circuit to the pump
Failure content
controller.
Phenomenon
occurring on
machine

1 (Disconnection or defec- Wiring harness between P02 (female) (9), (10) and CB2
tive contact with connec- Resistance
tor) value
2
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
(9), (10) and C02 (female) (21) and related circuits and
grounding
Pump controller position during the troubleshooting.
4
defective C02 Voltage
Between (21) and (31) 6–9V
P02 Voltage
Between (9), (10) and (20) 6–9V
20-318 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-319
(1)
Error Code in Electrical System [E128] (Monitor Comm. Abnormality)
User Code Error Code Failure Code Failure Monitor Comm. Abnormality
E0E E128 DAF0MC phenomenon (Monitor panel system)
• The monitor panel detected communication failure in the CAN communication circuit to the engine con-
Failure content
troller or pump controller.
Phenomenon
occurring on
machine
Relative
information

Disconnection of wiring
Wiring harness between P70 (female) (16) and CB2
harness Resistance
(female) (22) or between P70 (female) (16) and C02 Below 1 z
1 (Disconnection or defec- value
(female) (22)
tive contact with connec-
tor) Wiring harness between P70 (female) (15) and CB2
Resistance
value
(female) (32)
Between wiring harness between P70 (female) (16) and
Grounding fault of wiring CB2 (female) (22) or between P70 (female) (16) and Resistance
Above 1 Mz
harness C02 (female) (22) or between P70 (female) (16) and value
2
(Contact with grounding related circuits and grounding

Presumed cause and
circuit) Between wiring harness between P70 (female) (15) and

CB2 (female) (32) or between P70 (female) (15) and Resistance
Above 1 Mz
C02 (female) (32) or between P70 (female) (15) and value
related circuits and grounding
CB2 (female) (22) or between P70 (female) (16) and
Short-circuiting of wiring Voltage Below 1 V
C02 (female) (22) or between P70 (female) (16) and
3 harness
(Contact with 24 V circuit)
Voltage Below 1 V
CAN terminal resistor position during the troubleshooting.
4
defective K30 (male), K31 (male) Voltage
Between (1) and (2) 40 – 80 z
Monitor panel, engine If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 controller, or pump may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
controller defective ried out.)
20-320 PC400/450(LC)-7
(1)
Electrical circuit diagram related to CAN communication
PC400/450(LC)-7 20-321
(1)

(Short-circuiting in travel interlocking solenoid)
User Code Error Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected)
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No.: 02300 Solenoid 1)

Travel interlocking sole- position during the troubleshooting.
noid defective V02 (male) Resistance value
1
or grounding fault) Between (1) and (2) 20 – 60 z

Presumed cause and

2
(Contact with grounding Between wiring harness from C03 (female) (7) to V02 Resistance Above
circuit) (female) (2) and grounding value 1 Mz
a Turn the engine starting switch OFF for the preparations, and hold it running during
the troubleshooting.
Pump controller R.H. & L.H. travel control
3 C03 Voltage
defective lever
Between (7) and Neutral Below 1 V
grounding Steering 20 – 30 V
Electrical Circuit for Travel Interlocking Solenoid
20-322 PC400/450(LC)-7
(1)

(Short-circuiting in swing holding brake solenoid)
User Code Error Code Failure Code Failure Short-circuiting in swing holding brake solenoid
E03 E203 DW45KB phenomenon (Pump controller system)
• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the
Failure content
circuit.
• Power supply to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to
controller
normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing. (The swing holding brake cannot be released.)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the swing holding brake releasing switch to the RELEASE position.
(In this case, however, the holding brake does not work, when stopping the machine)

Swing holding brake position during the troubleshooting.
solenoid defective V05 (male) Resistance value
1

Presumed cause and
harness
2 Wiring harness from C03 (female) (37) to D01 to J02 to
(Contact with grounding Resistance Above
circuit) X05 to V05 (female) (2), or C03 (female) (37) and S25
value 1 Mz
(female) (8) and grounding
Pump controller L.H. work equipment
3 C03 Voltage
defective control lever
Between (37) and NEUTRAL Below 1 V
grounding Swing operated 20 – 30 V
20-324 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400/450(LC)-7 20-325
(1)
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)
User Code Error Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
occurring on
(F•R pumps cannot be disconnected.)
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.

Merge/divide solenoid position during the troubleshooting.
defective V03 (male) Resistance value
1

Presumed cause and
2
(Contact with grounding Wiring harness from C03 (female) (17) to V03 (female) Resistance Above
circuit) (2) and grounding value 1 Mz
L.H. and R.H. travel
Pump controller C03 Voltage
3 control levers
defective
NEUTRAL Below 1 V
Between (17) and
grounding When operating one side
20 – 30 V
only
Electrical Circuit Diagram for Merge/Divide Solenoid
20-326 PC400/450(LC)-7
(1)
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set.)
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid position during the troubleshooting.
1

Presumed cause and

2
Pump controller C03 Working mode Voltage
3
defective
Between (28) and Other than L mode Below 1 V
grounding L mode 20 – 30 V
Electric Circuit Diagram for 2-stage Relief Solenoid
PC400/450(LC)-7 20-327
(1)

(Short-circuiting in travel speed shifting solenoid)
User Code Error Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum.)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.

Travel speed shifting position during the troubleshooting.
solenoid defective V04 (male) Resistance value
1

Presumed cause and

2
Pump controller C03 Travel speed + travel lever Voltage
3
defective
Between (27) and Lo + Neutral Below 1 V
grounding Hi + Travel operation 20 – 30 V
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
20-328 PC400/450(LC)-7
(1)
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)
User Code Error Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (Pump controller system)
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative
• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
information
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E201].)

Travel interlocking position during the troubleshooting.
1 solenoid defective
V02 (male) Resistance value
(Internal disconnection)
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
Wiring harness from C03 (female) (7) to V02 (female) Resistance
(2) value
connector) Wiring harness between C03 (female) (3), (13), (23) Resistance
Below 1 z
and V02 (female) (1) value
Short-circuiting of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON
3
(Contact with 24 V cir- Wiring harness from C03 (female) (7) to V02 (female)
cuit) Voltage Below 1 V
(2) and grounding
4
defective C03 (female) Resistance value
Between (7) and (3), (13), (23) 20 – 60 z
Electrical Circuit Diagram for Travel Interlocking Solenoid
PC400/450(LC)-7 20-329
(1)

(Disconnection in swing holding brake solenoid)
User Code Error Code Failure Code Failure Disconnection in swing holding brake solenoid
E03 E213 DW45KA phenomenon (Pump controller system)
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
occurring on • The machine's upper structure does not swing. (The swing holding brake cannot be released.)
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can
swing by moving the swing holding brake release switch to the RELEASE position. (In this case,
Relative however, the holding brake does not work, when stopping the machine)
information • While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in
the OFF position.
[E203].)

Swing holding brake position during the troubleshooting.
Between (1) and (2) 20 – 60 z
Swing lock switch
2 defective X05 (female) Swing lock switch Resistance value
(Internal disconnection) OFF Below 1 z
Between (3) and (4)
ON Above 1 Mz
Assembled-type diode position during the troubleshooting.
3 D01 defective
D01 (male) Digital type circuit tester Continuity

Presumed cause and
Between (7) and (3) Diode mode Continued

Wiring harness between C03 (female) (37) and D01 Resistance
Disconnection of Below 1 z
(female) (7) value
wiring harness
Wiring harness from D01 (female) (3) to J02 to X05 Resistance
(male) (3) value
Wiring harness from X05 (male) (4) to V05 (female) (2) Below 1 z
value
Wiring harness between C03 (female) (3), (13), (23) Resistance
Below 1 z
Short-circuiting of position during the troubleshooting.
5 Wiring harness
(Contact with 24V circuit) Between wiring harness between C03 (female) (37) and Voltage Below 1 V
D01 (female) (7) and grounding
Pump controller
6 C03 (female) Disconnect D01 and Resistance value
defective
Between (37) and connect pins (3) and (7) of
the female side. 20 – 60 z
(3), (13), (23)
20-330 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Swing Holding Brake Solenoid
PC400/450(LC)-7 20-331
(1)
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)
User Code Error Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (Pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Phenomenon
• In L mode, speeds of the work equipment and swing in its single operation are too fast.
occurring on
(F•R pumps cannot be disconnected.)
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information
[E204].)

Merge/divide solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(2) value
Below 1 z
3
(Contact with 24 V Wiring harness from C03 (female) (17) to V03 (female)
(2) and grounding
4
Between (17) and (3), (13), (23) 20 – 60 z
Electrical Circuit Diagram for Merge/Divide Solenoid
20-332 PC400/450(LC)-7
(1)
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (Pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The one-touch power max. switch does not work.
occurring on
(The main relief valve cannot be set to high-pressure set.)
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information
[E205].)

2-stage relief solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(2) value
Below 1 z
3
(1) and grounding
4
Between (28) and (3), (13), (23) 20 – 60 z
Electrical Circuit Diagram for 2-stage Relief Solenoid
PC400/450(LC)-7 20-333
(1)
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)
User Code Error Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (Pump controller system)
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The travel motor swash plate angle does not turn to minimum.)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative
information
[E206].)

Travel speed shifting position during the troubleshooting.
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
(2) value
Below 1 z
3
(2) and grounding
4
Between (27) and grounding (3), (13), (23) 20 – 60 z
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
20-334 PC400/450(LC)-7
(1)
Error Code in Electrical System [E217] (Abnormal input model code)
User Code Error Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (Pump controller system)
Failure content • A model code signal for a model which is not registered in the controller is inputted.
• The controller controls the machine as a default model (PC750).
Response from
controller
Phenomenon
• Since the controller controls the machine as PC750/800, the working speed changes and operation
occurring on
becomes difficult.
machine
• The model name (number) recognized by the controller can be checked in the monitoring function.
Relative (Code No. 00200: Controller model code)
information • Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 02201: Switch input 2)

Model selection connec- position during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection or
short-circuit) Between (4), (5), (6) and (8) Min. 1 Mz
Between (1), (2), (3), (7) and (8) Max. 1 z
Wiring harness between C02 (female) (37) and C09 Resistance
Max, 1 z
(male) (1) value
Presumed cause and

harness Max, 1 z
(male) (2) value
2 (Disconnection or defec-
tive contact with connec- Wiring harness between C02 (female) (17) and C09 Resistance
Max, 1 z
tor) (male) (3) value
Max, 1 z
(male) (7) value
Wiring harness between C09 (male) (8), J05, and Resistance
Max, 1 z
grounding value
3
(Contact with grounding Between wiring harness between C02 (female) (7) and Resistance
circuit) Min. 1 Mz
C09 (male) (4) and grounding value
4 Pump controller defective C02 Voltage
Between (7) and grounding 5 – 30 V
Between (37), (27), (17), (13) and grounding Max. 1 V
20-336 PC400/450(LC)-7
(1)
Electrical circuit diagram related to model selection connector (for pump controller)
PC400/450(LC)-7 20-337
(1)
Error Code in Electrical System [E218] (S-Net Comm. Disc.)
User Code Error Code Failure Code Failure S-Net Comm. Disc.
E0E E218 DA2SKA phenomenon (Pump controller system)
• The pump controller detected communication failure in the S-NET communication circuit to the monitor
Failure content
panel or engine controller.
Phenomenon
occurring on
machine

1 (Disconnection or Wiring harness between P02 (female) (9), (10) and CB2
defective contact with Resistance
(female) (21), (31) or between P02 (female) (9), (10) Max. 1 z
connector) value
2
circuit) Min. 1 Mz
(9), (10) and C02 (female) (21) or between P02 (female) value
(9), (10) and related circuits and grounding
Presumed cause and

(Contact with 24 V circuit) and CB2 (female) (21), (31) or between P02 (female) Voltage Max. 1 V
(9), (10) and C02 (female) (21) or between P02 (female)
P02 Voltage
Between (9), (10) and (20) 6–9V
5
Between (21), (31) and (11) 6–9V
6 Pump controller defective
C02 Voltage
20-338 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for S-NET Communication
PC400/450(LC)-7 20-339
(1)
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)
User Code Error Code Failure Code Failure Disconnection in LS-EPC solenoid
— E222 DXE0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled.)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No.: 01500 LS-EPC solenoid current)

LS-EPC solenoid position during the troubleshooting.
1

Presumed cause and

2
(Contact with grounding Between wiring harness between C03 (female) (6) and Resistance Above
circuit) V22 (female) (1) and grounding value 1 Mz
Pump controller C03 (female) Resistance value
3
defective
Between (6) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for LS-EPC Solenoid
20-340 PC400/450(LC)-7
(1)
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)
User Code Error Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (Pump controller system)
Failure content • No current flows to the LS-EPC solenoid circuit.
Phenomenon
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
occurring on
fast. (The LS valve set pressure cannot be controlled.)
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No.: 01500 LS-EPC solenoid current)

LS-EPC solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
Between wiring harness between C03 (female) (6) and Resistance
V22 (female) (1) and grounding value
connector) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 z
V22 (female) (2) value
3
(Contact with 24 V Between wiring harness between C03 (female) (6) and
V22 (female) (1) and grounding
C03 (female) Resistance value
Between (6) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for LS-EPC Solenoid
PC400/450(LC)-7 20-341
(1)
Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure F Pump P. Sensor Abnormality
— E224 DHPAMA phenomenon (Pump controller system)
Failure content • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the F pump pressure to 0 MP {0 kg/cm2} for control.
Phenomenon
occurring on • The travel speed does not shift automatically (The travel load pressure cannot be detected).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01100: Front pump pressure)

Sensor power supply
1 If error code [226] is displayed, carry out troubleshooting for it first.
system defective
a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
A51 Voltage
Front pump pressure
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
Disconnection of wiring Wiring harness between C01 (female) (22) and A51 Resistance
harness Max. 1 z
Presumed cause and
(female) (B) value

3 (Disconnection or
defective contact with Wiring harness between C01 (female) (10) and A51 Resistance
Max. 1 z
connector) (female) (A) value
Wiring harness between C01 (female) (8) and P30 Resistance
Max. 1 z
(female) (C) value
4
circuit) Min. 1 Mz
A51 (female) (C) and grounding value
Between wiring harness between C01 (female) (22) and
5 harness Voltage Max. 1 V
A51 (female) (B) and grounding
Voltage Max. 1 V
A51 (female) (C) and grounding
Between (22) and (10) 4.5 – 5.5 V
Between (8) and (10) 0.5 – 4.5 V
20-342 PC400/450(LC)-7
(1)
Electrical circuit diagram related to front pump pressure sensor
PC400/450(LC)-7 20-343
(1)
Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure R Pump P. Sensor Abnormality
— E225 DHPBMA phenomenon (Pump controller system)
Failure content • Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the R pump pressure to 0 MP {0 kg/cm2} for control.
Phenomenon
occurring on • The travel speed does not shift automatically (The travel load pressure cannot be detected).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
information • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01101: Rear pump pressure)

Sensor power supply
system defective
A52 Voltage
Rear pump pressure
Between (B) and (A) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (C) and (A) Signal 0.5 – 4.5 V
Disconnection of wiring Wiring harness between C01 (female) (22) and A52 Resistance
harness Max. 1 z
Presumed cause and
(female) (B) value

3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) (10) and A52 Resistance
Max. 1 z
tor) (female) (A) value
Wiring harness between C01 (female) (2) and A52 Resistance
Max. 1 z
(female) (C) value
4
circuit) Min. 1 Mz
A52 (female) (C) and grounding value
A52 (female) (B) and grounding
Voltage Max. 1 V
A52 (female) (C) and grounding
Between (22) and (10) 4.5 – 5.5 V
Between (2) and (10) 0.5 – 4.5 V
20-344 PC400/450(LC)-7
(1)
Electrical circuit diagram related to rear pump pressure sensor
PC400/450(LC)-7 20-345
(1)
Error Code in Electrical System [E226] (Press. Sensor Power Abnormality)
User Code Error Code Failure Code Failure Press. Sensor Power Abnormality
— E226 DA25KP phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
• Power to the power supply (5 V) circuit is switched OFF.
Response from
controller
Phenomenon
• The pressure sensor signal is not input normally.
occurring on
• The error code of abnormality in the pressure sensor is displayed, too.
machine
Relative
information

a Disconnect the connector when the engine starting switch is in OFF, and hold it in
the ON position during the troubleshooting.
Front pump
Connector A51
pressure sensor
Pressure sensor Disconnect the parts
shown at right in order. Rear pump
1 defective Connector A52
If the error code goes off pressure sensor
when one of those parts is Arm IN PPC
disconnected, that part is Connector S04
pressure sensor
defective.
Bucket CURL PPC
Connector S01
pressure sensor
Presumed cause and
Between wiring harness between C01 (female) (22),
Resistance
A51 (female) (B) and grounding Min. 1 Mz
value
[Front pump pressure sensor system]
Grounding fault of wiring Between wiring harness between C01 (female) (22),
Resistance
harness A51 (female) (B) and grounding Min. 1 Mz
2 value
(Contact with grounding [Rear pump pressure sensor system]
circuit) Between wiring harness between C01 (female) (22),
Resistance
S04 (female) (A) and grounding Min. 1 Mz
value
[Arm IN PPC pressure sensor system]
Between wiring harness between C01 (female) (22),
Resistance
S01 (female) (A) and grounding Min. 1 Mz
value
[Bucket CURL PPC pressure sensor system]
C01 Voltage
Between (22) and (10) 4.5 – 5.5 V
20-346 PC400/450(LC)-7
(1)
Electrical circuit diagram related to pressure sensor power supply
PC400/450(LC)-7 20-347
(1)
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)
User Code Error Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (Pump controller system)
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
• The machine lacks power a bit. (The engine rotation sensing does not work.)
occurring on
• The engine speed (in the pump controller system) is not monitored on the monitor panel.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No.: 01006 Engine RPM)

Engine rotation sensor position during the troubleshooting.
fault ENE (male) Resistance value
1
or disconnection) Between (1) and (2) 500 – 1,000 z
Engine rotation sensor For the inspection and adjustment, refer to the section of “Adjusting Engine Rotation
2
adjustment improper Sensor” in this manual.
Presumed cause and

harness
Wiring harness between C02 (female) (40) and ENE Resistance
(female) (1) value
connector) Wiring harness between C02 (female) (29) (39) and Resistance
Below 1 z
ENE (female) (2) value
4
ENE (female) (1) and grounding
5
defective
Between (40) and (29) (39) 500 – 1,000 z
Electrical Circuit Diagram for Engine Rotation Sensor
20-348 PC400/450(LC)-7
(1)

(Short-circuiting in attachment return switching relay)
User Code Error Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (Pump controller system)
• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power
Failure content
ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
• The hydraulic circuit for attachments is not switched to the single operation circuit.
occurring on
(The switching valve is not switched to the tank circuit.)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No.: 02301 Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return selector
relay and cannot detect abnormality on the secondary side (contact side).

Attachment return position during the troubleshooting.
1 switching relay defective
R20 (male) Resistance value
Presumed cause and
Between (1) and (2) 100 – 500 z

2
R20 (female) (2) and grounding
3
defective
Between (8) and Other than B mode 20 – 30 V
grounding B mode Below 1 V
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400/450(LC)-7 20-349
(1)
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)
User Code Error Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to OFF.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled.)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be
Relative
operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the
information
emergency position. (At that time the monitor panel continues to display Error Code No. [E233], but this
is not abnormal)
• Turn the emergency driving switch normal position during the troubleshooting.

PC-EPC solenoid position during the troubleshooting.
1
Emergency pump driving Emergency pump drive

switch defective S25 (male) Resistance value
Presumed cause and
2 switch
or grounding fault) Between (3) and (4) Above 1 Mz
Between (3) and Normal
Above 1 Mz
grounding
harness Between wiring harness from C03 (female) (16) to S25 Resistance Above
3
(Contact with grounding (female) (3) and grounding value 1 Mz
circuit) Between wiring harness from S25 (female) (2) to V21 Resistance Above
(female) (1) and grounding value 1 Mz
4
defective
Between (16) and (3) (13) (23) 7 – 14 z
20-350 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for PC-EPC Solenoid
PC400/450(LC)-7 20-351
(1)
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)
User Code Error Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (Pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
occurring on
(The pump absorption torque cannot be controlled.)
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
Relative
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be
information
operated in a working mode equivalent to E mode by turning the emergency pump driving switch to the
emergency position.

PC-EPC solenoid position during the troubleshooting.
1 defective
Between (1) and (2) 7 – 14 z
Emergency pump driving
S25 (male) Resistance value
Emergency pump driving switch
2 switch defective Normal Below 1 z
(Internal disconnection) Between (2) and (3)
Emergency Above 1 Mz
Normal Below 1 z
Between (5) and (6)
Emergency Above 1 Mz
Presumed cause and
Wiring harness between C03 (female) (16) and S25 Resistance
Disconnection of wiring Below 1 z
(female) (3) value
harness
Wiring harness between S25 (female) (2) and V21 Resistance
(female) (1) value
connector) Wiring harness between C03 (female) (3) (13) (23) and Resistance
Below 1 z
S25 (female) (6) value
Wiring harness between S25 (female) (5) and V21 Resistance
Below 1 z
(female) (2) value
Short-circuiting of wiring position during the troubleshooting.
harness Between wiring harness between C03 (female) (16) and
4 Voltage Below 1 V
(Contact with 24 V S25 (female) (3) and grounding
circuit) Between wiring harness between S25 (female) (2) and
Voltage Below 1 V
5
Between (16) and (3) (13) (23) 7 – 14 z
20-352 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for PC-EPC Solenoid
PC400/450(LC)-7 20-353
(1)
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)
User Code Error Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (Pump controller system)
• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V
Failure content
voltage is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
• The hydraulic circuit for attachments cannot be switched to the single operation.
occurring on
(The switching valve cannot be switched to the tank circuit.)
machine
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
Relative or OFF). (Code No.: 02301 Solenoid 2)
information • This error code detects abnormality on the primary side (coil side) of the attachment return selector
relay and cannot detect abnormality on the secondary side (contact side).

If fuse No.2 has been blown, there is a big possibility that grounding fault occurred in
1 Fuse No. 2 fault
the relay circuit. (See Cause 4.)
Attachment return position during the troubleshooting.
2 switching relay defective
R20 (male) Resistance value
Between (1) and (2) 100 – 500 z
Disconnection in wiring position during the troubleshooting.

Presumed cause and
harness (Disconnection Wiring harness between C02 (female) (8) and R20 Resistance
3 Below 1 z
in wiring or defective (female) (2) value
contact in connector) Wiring harness from R20 (female) (1) to J03 to FB1-2 Resistance
Below 1 z
outlet value
harness Between wiring harness between C02 (female) (8) and Resistance Above
4
(Contact with grounding R20 (female) (2) and grounding value 1 Mz
circuit) Between wiring harness from R20 (female) (1) to J03 to Resistance Above
FB1-2 outlet and grounding value 1 Mz
5
defective
Between (8) and Other than B mode 20 – 30 V
grounding B mode Below 1 V
20-354 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400/450(LC)-7 20-355
(1)

(Short-circuiting in attachment oil flow rate adjusting EPC)
User Code Error Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC (Pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)

Attachment oil flow rate position during the troubleshooting.
adjusting EPC defective V30 (male) Resistance value
1

Presumed cause and

2
circuit) V30 (female) (1) and grounding value 1 Mz
3
defective
Between (26) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
20-356 PC400/450(LC)-7
(1)

(Disconnection in attachment oil flow rate adjusting EPC)
User Code Error Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC (Pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
Attachment oil flow rate a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
adjusting EPC defective position during the troubleshooting.
1
(Internal short-circuiting V30 (male) Resistance value

Presumed cause and
harness
Between wiring harness between C03 (female) (26) and Resistance
V30 (male) (1) and grounding value
connector) Between wiring harness between C03 (female) (3) (13) Resistance
Below 1 z
(23) and V30 (male) (2) and grounding value
3
4
Between (26) and (3) (13) (23) 7 – 14 z
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400/450(LC)-7 20-357
(1)

(Arm IN PPC pressure sensor abnormality)
User Code Error Code Failure Code Failure Arm IN PPC pressure sensor abnormality
— E247 DHS3MA phenomenon (Pump controller system)
Failure content • Signal voltage from the arm IN PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the arm IN PPC pressure to 0 MP {0 kg/cm2} for control.
Phenomenon
• If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The
occurring on
arm IN PPC circuit pressure cannot be detected).
machine
a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure
information • Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 07200: Arm IN PPC pressure)

Sensor power supply
system defective
S04 Voltage
Arm IN PPC pressure
Between (A) and (C) Power supply 4.5 – 5.5 V
2 sensor defective
(Internal defect) Between (B) and (C) Signal 0.5 – 4.5 V
The pressure voltage is measured with the wiring harness connected. Accordingly, if
the voltage is abnormal, check the wiring harness and controller, too, for another
cause of the trouble, and then judge.
Disconnection of wiring Wiring harness between C01 (female) (22) and S04 Resistance
Max. 1 z
Presumed cause and
harness (female) (A) value

3
(Disconnection or defec- Wiring harness between C01 (female) (10) and S04 Resistance
tive contact with connector) Max. 1 z
(female) (C) value
Max. 1 z
(female) (E) value
4
circuit) Min. 1 M z
S04 (female) (E) and grounding value
S04 (female) (A) and grounding
Voltage Max. 1 V
S04 (female) (B) and grounding
Between (22) and (10) 4.5 – 5.5 V
Between (19) and (10) 0.5 – 4.5 V
20-358 PC400/450(LC)-7
(1)
Circuit diagram related to arm IN PPC pressure sensor
PC400/450(LC)-7 20-359
(1)
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)
User Code Error Code Failure Code Failure Bucket CURL PPC pressure sensor abnormality
— E248 DHS4MA phenomenon (Pump controller system)
Failure content • Signal voltage from the bucket CURL PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from • The controller sets the bucket CURL PPC pressure to 0 MP {0 kg/cm2} for control.
Phenomenon
• If auto deceleration is operated, when auto deceleration cannot be released when moving the bucket
occurring on
CURL (The bucket CURL PPC circuit pressure cannot be detected).
machine
a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure
information • Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 07300: Bucket CURL PPC pressure)

Sensor power supply
system defective
S04 Voltage
Bucket CURL PPC pres-
Between (1) and (3) Power supply 4.5 – 5.5 V
2 sure sensor defective
(Internal defect) Between (2) and (3) Signal 0.5 – 4.5 V
Max. 1 z
Presumed cause and
harness (female) (1) value

3
(Disconnection or defec- Wiring harness between C01 (female) (10) and S04 Resistance
tive contact with connector) Max. 1 z
(female) (3) value
Max. 1 z
(female) (2) value
4
circuit) Min. 1 Mz
S04 (female) (2) and grounding value
S04 (female) (1) and grounding
Voltage Max. 1 V
Between (22) and (10) 4.5 – 5.5 V
Between (13) and (10) 0.5 – 4.5 V
20-360 PC400/450(LC)-7
(1)
Circuit diagram related to bucket CURL PPC pressure sensor
PC400/450(LC)-7 20-361
(1)
Error Code in Electrical System [E257] (Pump Abnormality)
User Code Error Code Failure Code Failure Pump Abnormality

E0E E257 DA2RMC phenomenon (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or engine controller.
Phenomenon
occurring on
machine
Relative
information

harness Resistance
1 (Disconnection or defec- value
(female) (22)
tor) Wiring harness between P70 (female) (15) and CB2
Resistance
value
(female) (32)
Above 1 Mz
2

Presumed cause and

Above 1 Mz
3 harness
Voltage Below 1 V
4
defective K30 (male), K31 (male) Resistance value
Between (1) and (2) 40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
pump controller defective ried out.)
20-362 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-363
(1)
Error Code in Electrical System [E315] (Battery Relay Drive S/C)
User Code Error Code Failure Code Failure Battery Relay Drive S/C
— E315 D110KB phenomenon (Pump controller system)
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit.
Phenomenon
occurring on • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
machine
Relative • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 03700: Controller output 1)

Battery relay defective
1 (Internal short-circuiting Battery relay (Unit) Resistance value
or grounding fault) Between BR and E Approx. 100 z
Presumed cause and
Between BR and grounding Min. 1 Mz

harness Between wiring harness between C03 (female) (4), D01,
2
(Contact with grounding J01, battery relay terminal BR or between C03 (female) Resistance
circuit) Min. 1 Mz
(4) and starting switch terminal B or between C03 value
(female) (4) and D01 (female) (2) and grounding
Pump controller
3 C03 (female) Starting switch Voltage
defective
20 – 30 V
Between (4) and grounding ON o OFF
(For 0.5 sec)
20-364 PC400/450(LC)-7
(1)
Electrical circuit diagram related to battery relay drive
PC400/450(LC)-7 20-365
(1)
TROUBLESHOOTING E91B
Error Code in Electrical System [E91B] (Engine Ne sensor problem)
User Code Error Code Failure Code Failure Engine Ne sensor problem
E11 E91B DLE3LC phenomenon (Engine controller system)
Failure content • Cranking angle cannot be judged from the engine Ne speed sensor signal.
Response from • The machine is driven with limited output.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idling.
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
Relative
(Code No. 01002: Engine speed)
information
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor.

Engine Ne speed sensor position during the troubleshooting.
defective NE (male) Resistance value
1
short-circuiting) Between (1) and (2) 85 – 210 z
Between (1), (2) and grounding Above 1 Mz
harness
Wiring harness between CB2 (female) (36) and NE Resistance
Presumed cause and
2 (Disconnection or defec- Below 1 z

(female) (2) value
tor) Wiring harness between CB2 (female) (26) and NE Resistance
Below 1 z
(female) (1) value
harness Between wiring harness between CB2 (female) (36) and Resistance
3 Above 1 Mz
(Contact with grounding NE (female) (2) and grounding value
circuit) Between wiring harness between CB2 (female) (26) and Resistance
Above 1 Mz
NE (female) (1) and grounding value
Engine controller CB2 (female) Resistance value
4
defective
Between (36) and (26) 85 – 210 z
Electrical circuit diagram related to engine Ne speed sensor
20-366 PC400/450(LC)-7
(1)
TROUBLESHOOTING E91C
Error Code in Electrical System [E91C] (Engine G sensor problem)
User Code Error Code Failure Code Failure Engine G sensor problem
E11 E91C DLH1LC phenomenon (Engine controller system)
Failure content • Cylinder cannot be judged from the engine G speed sensor signal.
• The machine is driven with limited output.
Response from
• Control is carried out with the Ne speed sensor signal.
controller
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Relative
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
information

Engine G speed sensor position during the troubleshooting.
defective G (male) Resistance value
1
short-circuiting) Between (1) and (2) 1.4 k – 3.5 kz
harness
Wiring harness between CB2 (female) (35) and G Resistance
Presumed cause and
(female) (2) value
connector) Wiring harness between CB2 (female) (25) and G Resistance
Below 1 z
(female) (1) value
3 Above 1 Mz
(Contact with grounding G (female) (2) and grounding value
Above 1 Mz
G (female) (1) and grounding value
Engine controller E12 (female) Resistance value
4
defective
Between (35) and (25) 1.4 k – 3.5 kz
Electrical circuit diagram related to engine G speed sensor
PC400/450(LC)-7 20-367
(1)
Error Code in Electrical System [E920] (Engine type selection error)
User Code Error Code Failure Code Failure Engine type selection error
E11 E920 DB29KQ phenomenon (Engine controller system)
• The model selection signal directly taken by the engine controller does not conform to the model in the
Failure content
controller or it is not confirmed.
• Control is carried out with the default model (PC400).
Response from
controller
• The model name (figure) recognized by the controller can be checked in the monitoring function.
Relative (Code No. 00201: Controller model code)
information • Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input state)

Model selection
connector defective CB5 (female) Resistance value
1
(Internal disconnection or Between (2), (3) (4), (5), (6), (7), and
short-circuiting) Above 1 Mz
(8)
Between (1) and (8) Below 1 z

harness
Presumed cause and
Wiring harness between CB1 (female) (3) and CB5 Resistance

(male) (1) value
connector) Wiring harness between CB2 (female) (1) and CB5 Resistance
Below 1 z
(male) (8) value
3 Above 1 Mz
(Contact with grounding CB5 (male) (2) and grounding value
Above 1 Mz
CB5 (male) (3) and grounding value
Engine controller CB1, CB2 Voltage
4
defective
Between CB1 (23), (17) and CB2 (1) 20 – 30 V
Between CB1 (3) and CB2 (1) Below 1 V
20-368 PC400/450(LC)-7
(1)
Electrical circuit diagram related to model selection connector (for engine controller)
PC400/450(LC)-7 20-369
(1)
Error Code in Electrical System [E921] (Engine type mismatch)
User Code Error Code Failure Code Failure Engine type mismatch
E11 E921 DB20KQ phenomenon (Engine controller system)
• The model information taken by the engine controller through the model selection connector does not
Failure content
conform to the model information taken from the pump controller by communication.
• The normal operation is continued.
Response from
controller
• The model name (figure) recognized by the engine controller can be checked in the monitoring func-
Relative tion. (Code No. 00201: Controller model code)
information • The model name (figure) recognized by the pump controller can be checked in the monitoring function.
(Code No. 00200: Controller model code)

Presumed cause and
Model selection connec-

1 If error code [E920] is displayed, carry out troubleshooting for it.
tor system defective
Engine controller Engine controller may be defective. (Since trouble is in the controller, troubleshoot-
2
defective ing cannot be carried out.)
Pump controller may be defective. (Since trouble is in the controller, troubleshooting

cannot be carried out.)
20-370 PC400/450(LC)-7
(1)
Error Code in Electrical System [E931] (Fuel dial sys. error)
User Code Error Code Failure Code Failure Fuel dial sys. error
E14 E931 DK10KX phenomenon (Engine controller system)
Failure content • The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.
• If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or
100% after the engine is started.
Response from
• If the abnormality is detected while the engine is running, the fuel control dial signal just before the
controller
abnormality is detected is kept.
Phenomenon
occurring on • The engine speed cannot be controlled.
machine
Relative • Input from the fuel control dial (voltage) can be checked in the monitoring function.
information (Code No. 03000: Fuel control dial voltage)

Fuel control dial defective E06 (male) Resistance value
1 (Internal disconnection or
Between (1) and (3) 4.0 – 6.0 kz
short-circuiting)
Between (1) and (2) 0.25 – 7.0 kz
Between (3) and (2) 0.25 – 7.0 kz
Disconnection of wiring Wiring harness between CB2 (female) (19) and E06 Resistance
harness Below 1 z
(female) (1) value
2 (Disconnection or
defective contact with Wiring harness between CB2 (female) (10) and E06 Resistance
Below 1 z
connector) (female) (2) value

Presumed cause and
Wiring harness between CB2 (female) (29), (39), and Resistance

Below 1 z
E06 (female) (3) value
3 Above 1 Mz
(Contact with grounding E06 (female) (1) and grounding value
Above 1 Mz
E06 (female) (2) and grounding value
Between wiring harness between CB2 (female) (19) and
4 harness Voltage Below 1 V
E06 (female) (1) and grounding
Voltage Below 1 V
E06 (female) (2) and grounding
Engine controller CB2 Voltage
5
defective
Between (19) and (29), (39) 4.6 – 5.4 V
Between (10) and (29), (39) 0.3 – 4.5 V
20-372 PC400/450(LC)-7
(1)
Electrical circuit diagram related to fuel control dial
PC400/450(LC)-7 20-373
(1)
Error Code in Electrical System [E934] (Engine coolant sensor Hi error)
User Code Error Code Failure Code Failure Engine coolant sensor Hi error
E15 E934 DGE2KX phenomenon (Engine controller system)
Failure content • The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine water high temperature sensor is kept at 90°C.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
• Input from the engine water high temperature sensor (voltage and water temperature) can be checked
Relative in the monitoring function.
information (Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High tem-
perature))

Engine water high
temperature sensor
1 defective TWH (male) Resistance value
(Internal disconnection or Between (1) and (2) 3.5 k – 90 kz
short circuit)

Presumed cause and
harness
Wiring harness between CB2 (female) (27) and TWH Resistance
(female) (1) value
connector) Wiring harness between CB2 (female) (29), (39), and Resistance
Below 1 z
TWH (female) (2) value
3
(Contact with grounding Between wiring harness between E12 (female) (27) and Resistance
circuit) Above 1 Mz
TWH (female) (1) and grounding value
Engine controller CB2 Resistance value
4
defective
Between (27), (29) and (39) 3.5 k – 90 kz
Between (27), (29), (39) and grounding Above 1 Mz
20-374 PC400/450(LC)-7
(1)
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
PC400/450(LC)-7 20-375
(1)
Error Code in Electrical System [E936] (Engine oil press. sw. error)
User Code Error Code Failure Code Failure Engine oil press. sw. error
E15 E936 DDE2L6 phenomenon (Engine controller system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is opened (disconnected from grounding) while the engine is running.
• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine
Failure content
is stopped (the starting signal is OFF).
• The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the
engine is stopped (the starting signal is OFF).
Response from • None in particular.
Relative • Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring func-
information tion. (Code No. 17400: Engine controller input)

Engine low-oil pressure position and start the engine during the troubleshooting.
switch defective PSL Engine Resistance value
1
short-circuiting) Between terminal Stopped Below 1 z
and grounding Low idling Above 1 Mz
position and start the engine during the troubleshooting.
Engine high-oil pressure
switch defective PSH Engine Resistance value
2
(Internal disconnection or Stopped Below 1 z
short-circuiting) Between terminal
and grounding Running at 1,300 rpm
Above 1 Mz
or higher

harness
Presumed cause and
Resistance
3 (Disconnection or Wiring harness between CB1 (female) (21) and PSL Below 1 z
value
Wiring harness between CB1 (female) (15) and PSH Below 1 z
value
4 Above 1 Mz
(Contact with grounding PSL and grounding value
Above 1 Mz
PSH and grounding value
position and start the engine during the troubleshooting.
CB1 Engine Voltage
Between (21) and ground- Stopped Below 1 V
ing (Low-pressure switch
Engine controller signal) Low idling 20 – 30 V
5
defective
Between (15) and ground- Stopped Below 1 V
ing (High-pressure switch Running at 1,300 rpm
signal) 20 – 30 V
or higher
Carry out troubleshooting while the engine is running 15 seconds after the engine is
started.
20-376 PC400/450(LC)-7
(1)
Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
PC400/450(LC)-7 20-377
(1)
Error Code in Electrical System [E93C] (Engine boost sensor error)
User Code Error Code Failure Code Failure Engine boost sensor error
E11 E93C DH30KX phenomenon (Engine controller system)
Failure content • The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function.
Relative
(Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.

PIM Voltage
Boost pressure sensor
Between (3) and (1) Power supply 4.6 – 5.4 V
1 defective
(Internal defect) Between (2) and (1) Signal 0.5 – 4.5 V
Disconnection of wiring Wiring harness between CB2 (female) (9) and PIM Resistance
harness Below 1 z
(female) (3) value
2 (Disconnection or
defective contact with Wiring harness between CB2 (female) (29), (39), and Resistance
Below 1 z
connector) PIM (female) (1) value

Presumed cause and
Wiring harness between CB2 (female) (20) and PIM Resistance

Below 1 z
(female) (2) value
Grounding fault of wiring
harness Resistance
3 PIM (female) (3), or between CB2 (female) (9) and Above 1 Mz
(Contact with grounding value
circuit)
Between wiring harness between CB2 (female) (20) and Resistance
Above 1 Mz
PIM (female) (2) and grounding value
Short-circuiting of wiring Between wiring harness between CB2 (female) (9), and
4 harness PIM (female) (3), or between CB2 (female) (9) and Voltage Below 1 V
(Contact with 24 V circuit) related circuits and grounding
Voltage Below 1 V
PIM (female) (2) and grounding
5
defective
Between (9) and (29), (39) 4.6 – 5.4 V
Between (20) and (29), (39) 0.3 – 4.7 V
20-378 PC400/450(LC)-7
(1)
Electrical circuit diagram related to boost pressure sensor
PC400/450(LC)-7 20-379
(1)
TROUBLESHOOTING E93D
Error Code in Electrical System [E93D] (Engine fuel temp. sensor error)
User Code Error Code Failure Code Failure Engine fuel temp. sensor error
E15 E93D DGE4KX phenomenon (Engine controller system)
Failure content • The signal voltage from the fuel temperature sensor is above 4.5 V.
Relative • Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
information (Code No. 14201: Fuel temperature sensor voltage)

Fuel temperature sensor position during the troubleshooting.
defective THL (male) Resistance value
1
short-circuiting) Between (1) and (2) 0.3 k – 9 kz

Presumed cause and
harness
Wiring harness between E12 (female) (17) and THL Resistance
(female) (1) value
connector) Wiring harness between E12 (female) (29), (39) and Resistance
Below 1 z
THL (female) (2) value
3
circuit) Above 1 Mz
THL (female) (A) and grounding value
Engine controller CB2 Resistance value
4
defective Between (17), (29) and (39) 0.3 k – 9 kz
Between (17) and (29), (39) and
Above 1 Mz
grounding
20-380 PC400/450(LC)-7
(1)
TROUBLESHOOTING E93D
Electrical circuit diagram related to fuel temperature sensor
PC400/450(LC)-7 20-381
(1)
Error Code in Electrical System [E953] (Engine Comm. Abnormality)
User Code Error Code Failure Code Failure Engine Comm. Abnormality
E0E E953 DB2RMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or pump controller.
Phenomenon
occurring on
machine
Relative
information

harness Resistance
1 (Disconnection or value
(female) (22)
connector) Wiring harness between P70 (female) (15) and CB2
Resistance
value
(female) (32)
Above 1 Mz
2

Presumed cause and

Above 1 Mz
3 harness
Voltage Below 1 V
4
defective K30 (male), K31 (male) Resistance value
Between (1) and (2) 40 – 80 z
Monitor panel, If causes 1 – 4 are not detected, monitor panel, engine controller, or pump controller
5 engine controller, or may be defective. (Since trouble is in those devices, troubleshooting cannot be car-
pump controller defective ried out.)
20-382 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-383
(1)
Error Code in Electrical System [E954] (Short engine starter sw.)
User Code Error Code Failure Code Failure Short engine starter sw.
— E954 DD11KB phenomenon (Engine controller system)
Failure content • Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from • Starting switch signal is recognized to be OFF.
Phenomenon
occurring on • The machine operates normally.
machine
Relative • Input of starting switch signal C (ON or OFF) can be checked in the monitoring function.
information (Code No. 17400: Engine controller input)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF and
ON positions during the troubleshooting.
Starting switch defective Starting switch Resistance value
1
Between terminal B OFF Above 1 Mz
and terminal C START Below 1 z
Presumed cause and

Between wiring harness between starting switch termi-
Short-circuiting of wiring nal C, J01, and CB1 (female) (20) or between starting
2 harness switch terminal C and C01 (female) (17) or between
(Contact with 24 V circuit) starting switch terminal C and P01 (female) (4) or Voltage Below 1 V
between starting switch terminal C and R11 (female) (5),
or between starting switch terminal C or related circuits
and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
Engine controller
4 CB1 Starting switch Voltage
defective
Between (20) and ON
Below 1 V
grounding (Engine is running)
20-384 PC400/450(LC)-7
(1)
Electrical circuit diagram related to engine preheating, starting, charging
PC400/450(LC)-7 20-385
(1)
Error Code in Electrical System [E955] (Engine S-NET error)
User Code Error Code Failure Code Failure Engine S-NET error
E0E E955 DB2SMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the S-NET communication circuit to the moni-
Failure content
tor panel or pump controller.
Phenomenon
occurring on
machine

1 (Disconnection or Wiring harness between P02 (female) (9), (10) and CB2
defective contact with Resistance
connector) value
2
circuit) Above 1 Mz
(9), (10) and C02 (female) (21) or between P02 (female) value
Presumed cause and

(9), (10) and C02 (female) (21) or between P02 (female)
P02 Voltage
Between (9), (10) and (20) 6–9V
5
Between (21), (31) and (11) 6–9V
C02 Voltage
20-386 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-387
(1)
Error Code in Electrical System [E956] (Engine power failure (1))
User Code Error Code Failure Code Failure Engine power failure (1)
E10 E956 DB22KK phenomenon (Engine controller system)
Failure content • When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Phenomenon
• The engine stalls.
occurring on
• The engine cannot be started.
machine
Relative
information

Circuit breaker 7 If circuit breaker is turned OFF, the circuit probably has grounding fault, etc.
1
defective (See cause 4.)
Engine controller power a Turn the engine starting switch OFF for the preparations, and hold it in the ON
supply relay defective position during the troubleshooting.
2
(Internal disconnection or Replace the power supply relay with another one. If the condition
short-circuiting) R22
becomes normal, the relay is defective.
Wiring harness between CB3 (female) (1), (2), (21) and Resistance
Below 1 z
R22 (female) (5) value
Disconnection of wiring Resistance
harness Wiring harness between R22 (female) (3) and B27 Below 1 z
value
3 (Disconnection or
Resistance
Presumed cause and
defective contact with Wiring harness between B17 and battery relay B terminal Below 1 z
connector) value
Wiring harness between R22 (female) (1) and J02 Resistance
Below 1 z
(male) (1) value
Resistance
Wiring harness between R22 (female) (2) and grounding Below 1 z
value
Between wiring harness between CB3 (female) (1), (2), Resistance
Grounding fault of wiring Above 1 Mz
(21) and R22 (female) (5) and grounding value
harness
4 Between wiring harness between R22 (female) (3) and Resistance
(Contact with grounding Above 1 Mz
circuit) B27 value
Between wiring harness between R22 (female) (1) and
Resistance
J02 (male) (1) or between R22 (female) (1) and related Above 1 Mz
value
circuits and grounding
Engine controller E13 Starting switch Voltage
5
defective
Between (1), (2), (21) OFF Below 1 V
and (11), (31), (32) ON 20 – 30 V
20-388 PC400/450(LC)-7
(1)
Electrical circuit diagram related to engine controller power supply
PC400/450(LC)-7 20-389
(1)
Error Code in Electrical System [E957] (Engine power failure (2))
User Code Error Code Failure Code Failure Engine power failure (2)
E15 E957 D1D0KB phenomenon (Engine controller system)
Failure content • When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Relative
information

Engine controller power position during the troubleshooting.
1 supply relay defective
(Internal short-circuiting) Replace the power supply relay with another one. If the condition
R22
becomes normal, the relay is defective.

Presumed cause and
Between wiring harness between E13 (female) (1), (2),
(21) and R22 (female) (3) and grounding
Between wiring harness between R22 (female) (1) and
Voltage Below 1 V
J03, J06 (male) (2), or related circuits and grounding
Engine controller CB3 Starting switch Voltage
3
defective
Between (1), (2), (21) OFF Below 1 V
and (11), (31), (32) ON 20 – 30 V
20-390 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-391
(1)
TROUBLESHOOTING E95A
Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error)
User Code Error Code Failure Code Failure Engine Q-adj. sw. signal error
— E95A DB2AMA phenomenon (Engine controller system)
Failure content • The fuel injection amount adjustment switch of the controller is not set to the correct position.
Phenomenon
occurring on • Setting of the fuel injection amount adjustment switch cannot be changed.
machine
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring
Relative
function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection
information
amount adjustment switch)

Presumed cause and
Setting of fuel injection

amount adjustment If the fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting
1
switch of engine is wrong.
controller defective
Engine controller
2 If the cause is not detected, engine controller may be defective.
defective
20-392 PC400/450(LC)-7
(1)
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)
User Code Error Code Failure Code Failure Engine coolant sensor Lo error
E15 E96A DGE3L6 phenomenon (Engine controller system)
Failure content • The signal voltage from the engine water low temperature sensor is above 4.5 V.
• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temper-
Response from
ature sensor is effective, it is used as a substitute).
controller
• Input from the engine water low temperature sensor (voltage and water temperature) can be checked
Relative
in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107:
information
Engine water temperature (Low temperature))

Engine water low
temperature sensor
1 defective TWL (male) Resistance value
(Internal disconnection or Between (1) and (2) 0.3 k – 9 kz
short circuiting)

Presumed cause and
harness
Wiring harness between CB2 (female) (37) and TWL Resistance
(female) (1) value
tor) Wiring harness between CB2 (female) (29), (39), and Resistance
Below 1 z
TWL (female) (2) value
3
circuit) Above 1 Mz
TWL (female) (1) and grounding value
Engine controller E12 Resistance value
4
defective
Between (29), (37) and (39) 0.3 k – 9 kz
20-394 PC400/450(LC)-7
(1)
temperature)
PC400/450(LC)-7 20-395
(1)
Error Code in Electrical System [E970] (PCV1 over current)
User Code Error Code Failure Code Failure PCV1 over current
E11 E970 AD11KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV1 circuit.
• Power to the fuel supply pump PCV1 circuit is switched OFF.
Response from
controller
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idling.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
information

Fuel supply pump PCV1 position during the troubleshooting.
defective PCV1 (male) Resistance value
1
or grounding fault) Between (1) and (2) 2.3 – 5.3 z

Presumed cause and
2
(Contact with grounding Between wiring harness between CB3 (female) (12) and Resistance
circuit) Above 1 Mz
PCV1 (female) (1) value
PCV1 (female) (1)
Voltage Below 1 V
PCV1 (female) (2)
4
defective
Between (12) and (22) 2.3 – 5.3 z
Electrical circuit diagram related to fuel supply pump PCV1
20-396 PC400/450(LC)-7
(1)
Error Code in Electrical System [E971] (PCV2 over current)
User Code Error Code Failure Code Failure PCV2 over current
E11 E971 AD51KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV2 circuit.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV2 position during the troubleshooting.
defective PCV2 (male) Resistance value
1

Presumed cause and
2
circuit) Above 1 Mz
PCV2 (female) (1)
Voltage Below 1 V
PCV2 (female) (2)
4
defective
Between (13) and (23) 2.3 – 5.3 z
PC400/450(LC)-7 20-397
(1)
Error Code in Electrical System [E974] (PCV1 line cut)
User Code Error Code Failure Code Failure PCV1 line cut
E11 E974 AD11KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV1 circuit is disconnected.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV1
1 defective PCV1 (male) Resistance value
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z

Presumed cause and
harness
connector) Between wiring harness between CB3 (female) (22) and Resistance
Below 1 z
3
circuit) Above 1 Mz
4
defective
Between (12) and (22) 2.3 – 5.3 z
20-398 PC400/450(LC)-7
(1)
Error Code in Electrical System [E975] (PCV2 line cut)
User Code Error Code Failure Code Failure PCV2 line cut
E11 E975 AD51KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV2 circuit is disconnected.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel supply pump PCV2
1 defective PCV2 (male) Resistance value
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z

Presumed cause and
harness
connector) Between wiring harness between CB3 (female) (23) and Resistance
Below 1 z
3
circuit) Above 1 Mz
4
defective
Between (13) and (23) 2.3 – 5.3 z
PC400/450(LC)-7 20-399
(1)
Error Code in Electrical System [E977] (Rail press. sensor error)
User Code Error Code Failure Code Failure Rail press. sensor error
E11 E977 DH40KX phenomenon (Engine controller system)
Failure content • The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
Relative
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.

Common rail fuel PFUEL Voltage

pressure sensor Between (3) and (1) Power supply 4.6 – 5.4 V
1
defective Between (2) and (1) Signal 0.7 – 4.5 V
(Internal defect)
Disconnection of wiring Wiring harness between CB2 (female) (9) and PFUEL Resistance
harness Below 1 z
(female) (3) value
2 (Disconnection or
defective contact with Wiring harness between CB2 (female) (39) and PFUEL Resistance
Below 1 z

Presumed cause and
Wiring harness between CB2 (female) (40) and PFUEL Resistance

Below 1 z
(female) (2) value
harness Resistance
3 PFUEL (female) (3), or between CB2 (female) (9) and Above 1 Mz
(Contact with grounding value
related ciricuits and grounding
circuit)
Above 1 Mz
PFUEL (female) (2) and grounding value
Short-circuiting of wiring Between wiring harness between CB2 (female) (9) and
4 harness PFUEL (female) (3), or between CB2 (female) (9) and Voltage Below 1 V
(Contact with 24 V circuit) related ciricuits and grounding
Voltage Below 1 V
PFUEL (female) (2) and grounding
5
defective
Between (9) and (39) 4.6 – 5.4 V
Between (40) and (39) 0.7 – 4.5 V
20-400 PC400/450(LC)-7
(1)
Electrical circuit diagram related to common rail fuel pressure sensor
PC400/450(LC)-7 20-401
(1)
TROUBLESHOOTING E979, E97A
Error Code in Electrical System [E979] (Rail press. high)
User Code Error Code Failure Code Failure Rail press. high
E11 E979 AD00L2 phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)

Related systems If any other error code or failure code is displayed, carry out troubleshooting for it
1
defective first.
2 Fuel used improper Fuel used may be improper. Check it directly.

Presumed cause and
Electric system of
3 common rail fuel Carry out troubleshooting for error code [E977].
pressure sensor defective
Mechanical system of
The common rail fuel pressure sensor may have a mechanical defect. Check it
4 common rail fuel
directly.
pressure sensor defective
The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of
5 Overflow valve defective
ball. Check it directly.
6 Overflow piping clogged The overflow piping may be clogged. Check it directly.
7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
Error Code in Electrical System [E97A] (Rail press. abnormal)
User Code Error Code Failure Code Failure Rail press. abnormal
E11 E97A AD00MA phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
Response from
controller
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Common rail related
1 Carry out troubleshooting for error code [E979].
in normalcy device defective
20-402 PC400/450(LC)-7
(1)
Error Code in Electrical System [E97B] (Rail press. low)
User Code Error Code Failure Code Failure Rail press. low
E15 E97B AD10L3 phenomenon (Engine controller system)
Failure content • No-pressure feed by fuel supply pump (level 1) occurred.
Response from
controller

Related systems If any other error code or failure code is displayed, carry out troubleshooting for it
1
defective first.
2 Fuel used improper Fuel used may be improper. Check it directly.
Fuel low-pressure circuit A low-pressure circuit device may be defective. Referring to Note 1, carry out
3
device defective troubleshooting.

Presumed cause and
Fuel filter/strainer The fuel filter/strainer may be clogged. Referring to Note 2, carry out
4
clogged troubleshooting.
Electrical system of fuel
5 supply pump PCV1 Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975].
defective
Fuel supply pump
6 The fuel supply pump may be defective. Check it directly.
defective
Common rail fuel
7 pressure sensor The common rail fuel pressure sensor may be defective. Check it directly.
defective
8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
9 Fuel injector defective The fuel injector may be defective. Referring to Note 3, check it directly.
Note 1: Check the low-pressure circuit devices for the following points.
1) Insufficiency of fuel
2) Fixing and wear of feed pump and clogging of filter
3) Leakage from and clogging of low-pressure fuel piping
4) Malfunction of bypass valve and installation of wrong part (See Fig. 1)
5) Clogging of fuel filter
6) Entry of fuel in oil pan (Fuel leakage in head cover)
• Fuel low-pressure circuit pressure: 0.15 – 0.3 MPa {1.5 – 3.0 kg/cm2}
PC400/450(LC)-7 20-403
(1)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• 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 the gauze filter. If it is clogged, clean it.
2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
Note 3: Judge the condition of the fuel injector by 3) Run the engine and stall at each speed
k When performing the follow work, take care

measuring the fuel spill rate. (relieve the arm circuit by moving the arm
in). Measure the quantity of the fuel spilling
not to scald yourself with the fuel which be- in 1 minute under this condition.
comes hot (up to 90°C). a Limit of spill of fuel (Total of spill from 6
1) Disconnect the hose connected to the cen- cylinders)
tralized return spill tube adapters (at the rear
Stall speed (rpm) Limit of spill (cc/min)
of the engine).
2) Connect another hose to the spill tube end 1,600 960
so that spill fuel can be received in a con- 1,700 1,020
tainer.
1,800 1,080
1,900 1,140
2,000 1,200
20-404 PC400/450(LC)-7
(1)
TROUBLESHOOTING E97C, E97D
Error Code in Electrical System [E97C] (Rail press. too low)
User Code Error Code Failure Code Failure Rail press. too low
E11 E97C AD10MB phenomenon (Engine controller system)
Failure content • No-pressure feed by fuel supply pump (level 2) occurred.
• The machine is driven with limited output and speed.
Response from
controller

cause and
standard value Common rail-related
1 Carry out troubleshooting for error code [E97B].
Error Code in Electrical System [E97D] (Rail press. out of control)
User Code Error Code Failure Code Failure Rail press. out of control
E11 E97D AD10MA phenomenon (Engine controller system)
Failure content • Abnormal fuel pressure was generated in the common rail.
• The machine is driven under the normal control.
Response from
controller

cause and
standard value Common rail-related
1 Carry out troubleshooting for error code [E97B].
PC400/450(LC)-7 20-405
(1)
Error Code in Electrical System [E980] (Eng. Controller Abnormality)
User Code Error Code Failure Code Failure Eng. Controller Abnormality
E10 or E11 E980 DB20KT phenomenon (Engine controller system)
Failure content • The controller has abnormality in it.
• The machine is driven with limited output or all output is turned OFF.
Response from
controller
Phenomenon
occurring on
machine
• The engine stop and it cannot be started (when user code [E10] is displayed).
Relative
information

Presumed cause and
1 (Disconnection or
defective contact with Wiring harness between CB3 (female) (11), (31), (32) Resistance
Below 1 z
connector) and grounding value
Engine controller If cause 1 is not detected, the engine controller may be defective.
2
defective (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
20-406 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-407
(1)
Error Code in Electrical System [E981] (Fuel Injector 1 Disc.)
User Code Error Code Failure Code Failure Fuel Injector 1 Disc.
E11 E981 ADA1KA phenomenon (Engine controller system)
Failure content • Fuel injector 1 circuit is disconnected.
• Power to the fuel injector 1 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel injector 1 defective position during the troubleshooting.
1
(Internal disconnection) CN1 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
Wiring harness between CB3 (female) (14) and CN1 Resistance
(female) (1) value
connector) Wiring harness between CB3 (female) (24) and CN1 Resistance
Below 1 z
(female) (2) value
3
defective CB3 (female) Resistance value
Between (14) and (24) 0.4 – 1.1 z
Electrical circuit diagram related to fuel injector 1
20-408 PC400/450(LC)-7
(1)
E11 E982 ADB1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (6) and (16) 0.4 – 1.1 z
PC400/450(LC)-7 20-409
(1)
E11 E983 ADC1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
tor) Wiring harness between CB3 (female) (15) and CN3 Resistance
Below 1 z
(female) (2) value
3
Between (5) and (15) 0.4 – 1.1 z
20-410 PC400/450(LC)-7
(1)
E11 E984 ADD1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (26) and (36) 0.4 – 1.1 z
PC400/450(LC)-7 20-411
(1)
E11 E985 ADF1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (34) and (33) 0.4 – 1.1 z
20-412 PC400/450(LC)-7
(1)
E11 E986 ADF1KA phenomenon (Engine controller system)
Response from
controller
Phenomenon
occurring on
machine
Relative
information

1
Between (1) and (2) 0.4 – 1.1 z

Presumed cause and
harness
(female) (1) value
Below 1 z
(female) (2) value
3
Between (25) and (35) 0.4 – 1.1 z
PC400/450(LC)-7 20-413
(1)
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)
User Code Error Code Failure Code Failure Fuel Injector 1 – 3 S/C
E11 E98A ADAZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Fuel injector 1 defective
1 (Internal short-circuiting CN1 (male) Resistance value
Presumed cause and

Above 1 Mz
CN1 (female) (1) and grounding value
Above 1 Mz
Grounding fault of wiring CN1 (female) (2) and grounding value
4 Above 1 Mz
(Contact with grounding CN2 (female) (1) and grounding value
Above 1 Mz
Above 1 Mz
Above 1 Mz
20-414 PC400/450(LC)-7
(1)

Voltage Below 1 V
CN1 (female) (1) and grounding
Voltage Below 1 V

Presumed cause and

Voltage Below 1 V
Voltage Below 1 V
Voltage Below 1 V
CB3 (female) Resistance value
Engine controller Between (14) and (24) 0.4 – 1.1 z
6
defective Between (6) and (16) 0.4 – 1.1 z
Between (5) and (15) 0.4 – 1.1 z
Between (5), (6), (14), (15), (16), (24)
Above 1 Mz
and grounding
Electrical circuit diagram related to fuel injectors 1, 2, and 3
PC400/450(LC)-7 20-415
(1)
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)
User Code Error Code Failure Code Failure Fuel Injector 4 – 6 S/C
E11 E98B ADDZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF.
Response from
controller
Phenomenon
occurring on
machine
Relative
information

Presumed cause and

Above 1 Mz
Above 1 Mz
Grounding fault of wiring CN4 (female) (2) and grounding value
4 Above 1 Mz
(Contact with grounding CN5 (female) (1) and grounding value
Above 1 Mz
Above 1 Mz
Above 1 Mz
20-416 PC400/450(LC)-7
(1)

Voltage Below 1 V
Voltage Below 1 V

Presumed cause and

Voltage Below 1 V
Voltage Below 1 V
Voltage Below 1 V
CB3 (female) Resistance value
Engine controller Between (26) and (36) 0.4 – 1.1 z
6
defective Between (34) and (33) 0.4 – 1.1 z
Between (25) and (35) 0.4 – 1.1 z
Between (25), (26), (33), (34), (35), (36)
Above 1 Mz
and grounding
Electrical circuit diagram related to fuel injectors 4, 5, and 6
PC400/450(LC)-7 20-417
(1)
TROUBLESHOOTING A000N1, A000N2
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)
User Code Error Code Failure Code Failure Engine high-idling speed out of standard
E22 E922 A000N1 phenomenon (Mechanical system)
Failure content • While the engine is running, its speed above 2,350 rpm is detected.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01006: Engine speed)

Overrun of engine Check for an external or an internal factor which heightens the engine high-idling
1
Presumed cause and
(While system is normal) speed, and then check the mechanical system of the engine.
Engine speed sensor
2 If error code [E227] is displayed, carry out troubleshooting for it first.
system abnormal
a Turn the engine starting switch ON for the preparations, and keep the engine
Engine controller defec-
3 Monitoring Engine Engine speed
tive
01006
High idling 1,880 – 1,980 rpm
Engine speed
Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)
User Code Error Code Failure Code Failure Engine low-idling speed out of standard
— — A000N2 phenomenon (Mechanical system)
Failure content • While the engine is running, its speed below 500 rpm is detected.
Phenomenon
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01006: Engine speed)

Engine mechanical sys- Check for an external or an internal factor which lowers the engine low-idling speed,
1
Presumed cause and
tem defective and then check the mechanical system of the engine.
Engine speed sensor
2 If error code [E227] is displayed, carry out troubleshooting for it first.
system abnormal
a Turn the engine starting switch ON for the preparations, and keep the engine
Engine controller defec-
3 Monitoring Engine Engine speed
tive
01006
Low idling 975 – 1,025 rpm
Engine speed
20-418 PC400/450(LC)-7
(1)
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)
User Code Error Code Failure Code Failure Aircleaner Clogging

— — AA10NX phenomenon (Mechanical system)
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine
Failure content
is running.
Response from
controller
Phenomenon
machine
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this
Relative failure code is recorded.
information • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 1)

Air cleaner clogged
1 Check the air cleaner. If it is clogged, clean or replace it.
(While system is normal)
position or keep the engine running during the troubleshooting.
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) Normal Below 1 z

Presumed cause and
Between (1) and (2)

Clogged Above 1 Mz
harness
Wiring harness between P02 (female) (5) and A31 Resistance
(female) (1) value
Wiring harness between A31 (female) (2) and grounding Below 1 z
value
position or keep the engine running during the troubleshooting.
4 Monitor panel defective P02 Air cleaner Voltage
Normal Below 1 V
Between (5) and grounding
Clogged 20 – 30 V
20-420 PC400/450(LC)-7
(1)
TROUBLESHOOTING AA10NX
Electrical circuit diagram related to air cleaner clogging switch
PC400/450(LC)-7 20-421
(1)
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low)
User Code Error Code Failure Code Failure Charge Voltage Low
— — AB00KE phenomenon (Mechanical system)
Failure content • Signal voltage from alternator is below 20 V while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the battery may not be charged.
machine
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure
Relative code is recorded.
information • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No. 04300: Charge voltage, 04501: Monitor input 2)

Alternator defective Alternator Engine Voltage
1
(Internal defect) Between terminal R
Above low idling Above 20 V
and grounding
If the voltage is abnormal, check the belt tension too.

Presumed cause and
2 (Disconnection or
defective contact with Wiring harness between P02 (female) (11), J02, and Resistance
Below 1 z
connector) alternator terminal R value
harness Between wiring harness between P02 (female) (11),
3 J02, and alternator terminal R, or between P02 (female)
(Contact with grounding Resistance
circuit) (11), D01, J01, and starting switch terminal BR, or Above 1 Mz
value
between P02 (female) (11), battery relay terminal BR
and grounding
4 Monitor panel defective P02 Engine Voltage
Between (11) and
Above low idling Above 20 V
grounding
20-422 PC400/450(LC)-7
(1)
TROUBLESHOOTING AB00KE
Electrical circuit diagram related to engine preheating, starting, charging
PC400/450(LC)-7 20-423
(1)
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)
User Code Error Code Failure Code Failure Eng. Oil Press. Low
E11 E924 B@BAZG phenomenon (Mechanical system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm.
Failure content • The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal
circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above
1,300 rpm.
Response from
controller
Phenomenon
machine
• When this failure occurs, the error code is displayed only when the user code is turned ON and the fail-
ure code is recorded in only the mechanical system of the failure history.
Relative • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this
information failure code is recorded.
• Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input)

Engine oil pressure
Check the engine oil pressure. If it is abnormal, find out the cause and check the
1 lowered
engine for damage, then repair.
(While system is normal)
Engine oil pressure

2 Carry out troubleshooting for error code [E936].
Presumed cause and
switch system defective

position or start the engine during the troubleshooting.
CB1 Engine Voltage
Between (21) and grounding Stopped Below 1 V
Engine controller (Low-pressure switch signal)
3 Low idling 20 – 30 V
defective
Between (15) and grounding Stopped Below 1 V
(High-pressure switch signal) Above 1,300 rpm 20 – 30 V
When carrying out troubleshooting while the engine is running, wait for 15 seconds
after the engine is started.
20-424 PC400/450(LC)-7
(1)
TROUBLESHOOTING B@BAZG
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC400/450(LC)-7 20-425
(1)
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)
User Code Error Code Failure Code Failure Eng. Oil Level Low
— — B@BAZK phenomenon (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
Failure content
engine is stopped.
Response from
controller
Phenomenon
machine
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this fail-
Relative ure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.

Engine oil level low Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Engine oil level switch
2 defective OL (male) Engine oil level Resistance value

Presumed cause and
(Internal disconnection) Normal level Below 1 z

Below normal level Above 1 Mz
3 (Disconnection or
defective contact with Wiring harness between P02 (female) (8) and OL Resistance
Below 1 z
4 Monitor panel defective P02 Engine oil level Voltage
Normal level Below 1 V
Below normal level 20 – 30 V
Electrical circuit diagram related to engine oil level switch
20-426 PC400/450(LC)-7
(1)
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat)
User Code Error Code Failure Code Failure Eng. Water Overheat
— — B@BCNS phenomenon (Mechanical system)
Failure content • The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from
controller
Phenomenon
machine
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is run-
ning, this failure code is recorded.
Relative
• Input from the engine water high temperature sensor (water temperature and voltage) can be checked
information
in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine water
temperature sensor voltage Hi)

Engine overheated Check the engine for overheating. If it has been overheated, find out the cause and
1
Presumed cause and
(While system is normal) check the engine for damage, then repair.
Engine water high
Carry out troubleshooting for “Display of engine water temperature gauge on monitor
2 temperature sensor
panel is abnormal” in E mode.
system defective
3
defective CB2 (female) Engine water temperature Resistance value
Between (27) and (29), (39) 105°C 3.28 kz
temperature)
PC400/450(LC)-7 20-427
(1)
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)
User Code Error Code Failure Code Failure Eng. Water Lvl Low
— — B@BCZK phenomenon (Mechanical system)
• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the
Failure content
engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the engine will overheat.
machine
• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the
Relative starting switch is at the ON position), this failure code is recorded.
information • Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.

Sub-tank water level low Check the radiator sub-tank water level. If it is low, add water. (If it is reduced fre-
1
(While system is normal) quently, find out the cause.)
Radiator water level
2 switch defective A33 (male) Sub-tank water level Resistance value
(Internal disconnection) Within normal level Below 1 z

Presumed cause and
Between (1) and (2)

Below LOW level Above 1 Mz
harness
(female) (1) value
connector) Wiring harness between A33 (female) (2), J08, J12 and Resistance
Below 1 z
grounding value
4 Monitor panel defective P02 Sub-tank water level Voltage
Within normal level Below 1 V
Below LOW level 20 – 30 V
Electrical circuit diagram related to radiator water level switch
20-428 PC400/450(LC)-7
(1)
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)
User Code Error Code Failure Code Failure Hydr. Oil Overheat
— — B@HANS phenomenon (Mechanical system)
Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from
controller
Phenomenon
occurring on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func-
tion. (Code No. 04401: Hydraulic oil temperature)

Hydraulic oil overheated Check the hydraulic oil for overheating. If it has been overheated, find out the cause
1
(While system is normal) and check the hydraulic equipment for damage, then repair.
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value

Presumed cause and
(Internal short-circuiting) Between (1) and (2) 90 – 3.5 kz

10 – 100°C
3
(Contact with grounding Between wiring harness between P02 (female) (12) and Resistance
circuit) Above 1 Mz
A61 (female) (2) and grounding value
P02 Hydraulic oil temperature Resistance value
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Above 1 Mz
grounding
Electrical circuit diagram related to hydraulic oil temperature sensor
PC400/450(LC)-7 20-429
(1)
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503

E-1 The engine does not start (The engine does not rotate) ...................................................................... 20-504
E-2 Preheater does not operate.................................................................................................................. 20-508
E-3 Auto engine warm-up device does not work ........................................................................................ 20-510
E-4 Auto-decelerator does not operate ....................................................................................................... 20- 511
E-5 All work equipment, swing and travel do not move .............................................................................. 20-512
E-6 One-touch power max. function does not operate ............................................................................... 20-514
E-7 Machine push-up function does not operate normally.......................................................................... 20-515
E-8 Attachment circuit does not change ..................................................................................................... 20-517
E-9 No display in monitor panel at all ......................................................................................................... 20-519
E-10 Part of display on monitor panel is missing ........................................................................................ 20-520
E-11 Monitor panel displays contents irrelevant to the model..................................................................... 20-520
E-12 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-521
E-13 Engine water temperature gauge does not display correctly ............................................................. 20-522
E-14 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524
E-15 Fuel gauge does not display correctly ................................................................................................ 20-525
E-16 Swing lock monitor does not display correctly.................................................................................... 20-526
E-17 When monitor switch is operated, nothing is displayed...................................................................... 20-528
E-18 Windshield wiper and window washer do not work ............................................................................ 20-530
E-19 Alarm buzzer cannot be cancelled ..................................................................................................... 20-534
E-20 “Boom RAISE” is not correctly displayed in monitor function ............................................................. 20-535
E-21 “Boom LOWER” is not correctly displayed in monitor function........................................................... 20-536
E-22 “Arm IN” is not displayed normally in monitoring function .................................................................. 20-537
E-23 “Arm DUMPING” is not correctly displayed in monitor function.......................................................... 20-538
E-24 “Bucket CURL” is not displayed normally in monitoring function........................................................ 20-539
E-25 “Bucket DUMPING” is not correctly displayed in monitor function ..................................................... 20-540
E-26 “Swing” is not displayed normally in monitoring function.................................................................... 20-542
E-27 “TRAVEL” is not correctly displayed in monitor function..................................................................... 20-544
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function ....................................... 20-546
E-29 “Service” is not correctly displayed in monitor function ...................................................................... 20-548
E-30 Travel alarm does not sound or does not stop sounding.................................................................... 20-550
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.............................................................. 20-552
PC400/450(LC)-7 20-501
(1)
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Before carrying out troubleshooting for electrical system (E-mode)
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 at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if
the power is supplied normally.
Type of
Fuse No. Fuse capacity Destination of power
power supply
Pump controller (Controller power supply)
1 10 A Swing holding brake solenoid (When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
2 20 A Machine push-up solenoid
Switch power supply
ATT return selector relay & solenoid
(Fusible link: A34)
Starting motor cutout relay (For PPC lock)
3 10 A
PPC lock solenoid
Cigarette lighter
4 10 A
Windshield washer motor
5 10 A Horn
6 10 A (Spare)
7 10 A Rotary lamp
Switch power supply 8 10 A Right front working lamp & boom working lamp
(Fusible link: A34) One-touch power maximizing switch (Input to pump controller input)
9 10 A
Radio
10 10 A (Spare)
11 20 A Air conditioner unit
Monitor panel
12 20 A
Starting motor cutout relay (For personal code)
Switch power supply Light relay (For right front working lamp & boom working lamp)
13 20 A
(Fusible link: A34) Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
Travel alarm
15 10 A
Service power supply 2 (DC/DC converter)
16 10 A Radio (For backing up)
Constant power 17 10 A Monitor panel (For backing up)
supply 18 10 A Starting switch
(Fusible link: A35) 19 10 A Room lamp
20 10 A (Spare)
20-502 PC400/450(LC)-7
(1)

a The following information are edited and contained in the “Information Contained in Troubleshooting Table”.
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge “good” or “no good” about
1 presumed causes.
• References for making judgement of “good” or “no good”
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in

Presumed cause and
contact with it.

Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V)
(The attached No. for is in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a
4
connector and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a
connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the
5 following manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
PC400/450(LC)-7 20-503
(1)
TROUBLESHOOTING E-1
E-1 The engine does not start (The engine does not rotate)
Failure
• The engine does not start.
information
Relative
• The engine starting circuit has the start lock mechanism of the safety lock lever type
information

a Prepare with starting switch OFF, then carry out troubleshooting without turning
Insufficient battery starting switch ON.
1
capacity Battery voltage Electrolyte specific gravity
Min. 24 V Min. 1.26
Defective fusible link A35 If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has a
2
or fuse No. 3 or 17 grounding fault (See cause 9).
a Prepare with starting switch OFF, then keep starting switch OFF or turn it START
and carry out troubleshooting.
Defective starting switch H15 (male) Starting switch Resistance
3
OFF Min. 1 Mz
Between (1) and (4)
START Max. 1 z
starting switch ON.
Defective safety lock
4 switch S14 (female) Safety lock lever Resistance
(Internal short circuit)
FREE Min. 1 Mz
Between (1) and (3)
Presumed cause and
LOCK Max. 1 z
Defective starting motor R11 (female), R13 (female) Resistance
5 cut-out relay
Between (1) and (2) 100 – 500 z
(Internal defect)
Between (3) and (5) Min. 1 Mz
Between (3) and (6) Max. 1 z
a Prepare with starting switch OFF (with wiring harness connected), then turn
starting switch to START and carry out troubleshooting.
Starting motor Voltage
Between terminal B and B (Power
20 – 30 V
chassis ground supply)
Defective starting motor
6 Between ST (1) and chas-
(Internal defect) S (Start) 20 – 30 V
sis ground
Between ST (2) and chas-
R (Charge) Max. 1 V
sis ground
If the above voltage is normal and the starting motor does not rotate, starting motor
has a defect in it or the engine is defective.
a Prepare with starting switch OFF (with only wiring harness R disconnected), then
Defective alternator turn starting switch ON and carry out troubleshooting.
7
(Internal short circuit) Alternator Voltage
Between terminal R and chassis ground Max. 1 V
20-504 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-1

starting switch ON.
Wiring harness between battery relay B terminal and
Resistance Max. 1 z
A35 (male) (1)
Wiring harness between A35 (male) (2) and H15
Resistance Max. 1 z
(female) (1)
Disconnection in wiring Wiring harness between H15 (female) (4), J01, and
Resistance Max. 1 z
harness (Disconnection R11 (female) (5)
8 in wiring harness or Wiring harness between R11 (female) (3) and ST
Resistance Max. 1 z
defective contact in con- (female) (1)
nector) Wiring harness between FB1-3 and S14 (male) (1) Resistance Max. 1 z
Wiring harness between S14 (male) (3) and R11
Resistance Max. 1 z
(female) (1)
Wiring harness between R11 (female) (2) and R13
Resistance Max. 1 z
(female) (6)
Wiring harness between R13 (female) (3), J04, and

Resistance Max. 1 z
Presumed cause and
chassis ground
starting switch ON.
Between wiring harness between A35 (male) (2) and
Resistance Min. 1 Mz
H15 (female) (1) and chassis ground
Wiring harness between H15 (female) (4), J01, and
R11 (female) (5), and other related circuits and chassis Resistance Min. 1 Mz
ground
Short circuit with chas- Wiring harness between R11 (female) (3) and ST
sis ground in wiring har- (female) (1) and chassis ground
9
ness (Contact with Wiring harness between FB1-3 and S14 (male) (1) and
ground circuit) Resistance Min. 1 Mz
chassis ground
Wiring harness between A14 (male) (3) and R11
(female) (1) and chassis ground
Wiring harness between R11 (female) (2) and R13
Wiring harness between R13 (female) (2), J05, P02
(female) (14), and other related circuits and chassis Resistance Min. 1 Mz
ground
a Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power troubleshooting.
source in wiring harness
10 Between wiring harness between ST (female) (2),
(Contact with 24-V cir-
cuit) alternator terminal R, J02, D01 (female) (6), and P02 Voltage Max. 1 V
PC400/450(LC)-7 20-505
(1)
TROUBLESHOOTING E-1
Electrical circuit diagram for engine preheating, starting, charging
20-506 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-1
E-2 Preheater does not operate
Failure (1) When the starting switch is turned to the HEAT posi-
• The preheater does not operate.
information tion, the preheating monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
information • Input of the preheating signal (ON or OFF) can be checked in the monitoring function.

Starting switch system If the preheater does not operate (the heater unit is not warmed), carry out trouble-
1
defective shooting (2).
Presumed cause and

2 (Disconnection or
defective contact with Wiring harness between P02 (female) (18) and J02 Resistance
Below 1 z
connector) (male) (7) value
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
3 Monitor panel defective P02 Starting switch Voltage
Between (18) and OFF Below 1 V
grounding HEAT 20 – 30 V
Failure (2) When the starting switch is turned to the HEAT

• The preheater does not operate.
information position, the heater unit is not warmed.
Relative • Check that the starting motor rotates normally.
information • (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.)

a Turn the engine starting switch OFF for the preparations, and hold it in the OFF or
HEAT position during troubleshooting.
Starting switch defective H15 (male) Starting switch Resistance value
1
OFF Above 1 Mz
Between (1) and (3)
HEAT Below 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
Continuity and
Heater relay defective Heater relay Starting switch

2 resistance value
Presumed cause and
Between coil terminal
OFF Continued
and grounding
Between contact terminals HEAT Below 1 z
Intake air heater position during the troubleshooting.
3 defective
Intake air heater Continuity
Between terminals Continued
Wiring harness between H15 (female) (3), J02, and Resistance
Below 1 z
heater relay terminal value
Disconnection of wiring Wiring harness between starting motor terminal B and Resistance
harness Below 1 z
heater relay value
4 (Disconnection or
defective contact with Wiring harness between heater relay and intake air Resistance
Below 1 z
connector) heater value
Resistance
Wiring harness between intake air heater and engine Below 1 z
value
20-508 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-2
Electrical circuit diagram for engine preheating, starting, charging
PC400/450(LC)-7 20-509
(1)
TROUBLESHOOTING E-3
E-3 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below
30°C, and raise the engine rotation up to 1,200 rpm.
Relative • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
information than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine water temperature is below 10°C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

a Turn the starting switch ON for the troubleshooting (monitoring).
Presumed cause and
Monitoring code Item Normal display

Compare the monitor
Engine cooling water Engine cooling water
1 indication with the actual
temperature signal fault 04107 temperature
engine cooling water
(low temperature)
temperature.
If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine
water thermometer does not display normally”.
Engine controller If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
2
defective the engine controller, troubleshooting cannot be carried out.)
20-510 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-4
E-4 Auto-decelerator does not operate
Failure
• The auto-decelerator does not operate.
information
• Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above
this level.
Relative
• Check the display on the monitor panel while the engine is running.
information
• If the display on the monitor panel is abnormal, carry out troubleshooting in “ is not displayed
normally in monitoring function”.

Boom RAISE signal
1 01900 Lever operated: ON
defective Boom RAISE
Pressure switch 1 Lever in neutral: OFF
Boom LOWER signal
defective Boom LOWER
3 Arm IN signal defective 01900 Lever operated: ON
Arm IN
4 Arm OUT signal defective 01900 Lever operated: ON
Arm OUT

Presumed cause and

Bucket CURL signal
defective Bucket CURL
Bucket DUMP signal
defective Bucket DUMP
7 Swing signal defective 01900 Lever operated: ON
Swing
8 Travel signal defective 01900 Lever operated: ON
Travel
9 Service signal defective 01901 Lever operated: ON
Service
If causes 1 – 9 are not detected, the pump controller may be defective.
(Since trouble is in the pump controller, troubleshooting cannot be carried out.)
Engine controller If causes 1 – 9 are not detected, the engine controller may be defective.
11
defective (Since trouble is in the pump controller, troubleshooting cannot be carried out.)
PC400/450(LC)-7 20-511
(1)
TROUBLESHOOTING E-5
E-5 All work equipment, swing and travel do not move
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

If the fuse is blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 3 fault
circuit. (See cause 6.)
Safety lock switch
2 defective S14 (female) Safety lock lever Resistance value
(Internal disconnection) Free Below 1 z
Between (1) and (2)
Lock Above 1 Mz
PPC lock solenoid
defective
3 (Internal disconnection, V08 (male) Resistance value
short-circuiting, or Between (1) and (2) 20 – 60 z
grounding fault)
Presumed cause and
Assembled-type diode position during the troubleshooting.
4 D01 defective
D01 (male) Resistance value (Continuitiy)
Between (4) and (8) Above 1 Mz (No continuitiy)
Disconnection of wiring Wiring harness between FB1-3 outlet and S14 (male) Resistance
harness Below 1 z
(1) value
5 (Disconnection or
defective contact with Wiring harness from S14 (male) (2) and J02 – V01 Resistance
Below 1 z
Wiring harness between V08 (female) (1) to J13 and Resistance
Below 1 z
grounding value
Between wiring harness between FB1-3 outlet and S14 Resistance
harness Above 1 Mz
6 (male) (1) and grounding value
(Contact with grounding
circuit) Wiring harness from S14 (male) (2) to J02 – V01
Resistance
(female) (2), or between wiring harness between S14 Above 1 Mz
value
(male) (2) and D01 (female) (4) and grounding
20-512 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-5
Electrical circuit diagram for PPC lock solenoid
PC400/450(LC)-7 20-513
(1)
TROUBLESHOOTING E-6
E-6 One-touch power max. function does not operate
Failure
• One-touch power max. function does not operate
information
• If the one-touch power max. switch is pressed while the engine is running, the one-touch power max.
Relative monitor is displayed on the monitor panel.
information • Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in
the monitoring function. (Code No. 02200: Switch input 1)

If the fuse is broken, there is a big possibility that grounding fault occurred in the cir-
1 Fuse No. 9 defective
cuit. (See cause 4.)
One-touch power max. One-touch power
2 switch defective (Internal M23 (male) Resistance value
max. switch
disconnection)
Released Min. 1 Mz
Between (1) and (2)
Pressed Max. 1 z
Presumed cause and
harness (Disconnection position during the troubleshooting.

3
or defective contact with Wiring harness between FB1-9 outlet and M23 (female) Resistance
connector) Max. 1 z
(1) value
Grounding fault of wiring Between wiring harness between FB1-9 outlet and M23
Resistance
4 harness (Contact with (female) (1), or between wiring harness between FB1-9 Min. 1 Mz
value
grounding circuit) outlet and other related circuit and grounding
Between wiring harness between M23 (female) (2) and Resistance
Min. 1 Mz
C01 (female) (11) and grounding value
One-touch power
max. switch
Between (11) and Released Max. 1 V
grounding Pressed 20 – 30 V
Electrical circuit diagram related to one-touch power max. switch
20-514 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-7
E-7 Machine push-up function does not operate normally
Failure • Machine push-up function does not operate

(1) The machine push-up function does not operate.
information normally.
Relative
• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
information


Presumed cause and
Machine push-up switch

1 defective M38 (female) Machine push-up switch Resistance value
(Internal short-circuiting) Low pressure position Below 1 z
Between (1) and (2)
High pressure position Above 1 Mz
Short-circuiting of wiring position during troubleshooting.
2 harness Between wiring harness between M38 (female) (2), J07
(Contact with 24 V circuit) and V06 (female) (2) or between M38 (female) (2) and Voltage Below 1 V
Electrical circuit diagram related to machine push-up solenoid
PC400/450(LC)-7 20-515
(1)
TROUBLESHOOTING E-7
Failure • Machine push-up function does not operate

(2) The machine push-up function is not turned OFF.
information normally.
Relative
• When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
information

1 Fuse No. 2 defective If the fuse is broken, the circuit probably has grounding fault (See cause 6).
Machine push-up switch
2 defective M38 (female) Machine push-up switch Resistance value
(Internal disconnection) Low pressure position Below 1 z
Between (1) and (2)
High pressure position Above 1 Mz
Machine push-up
solenoid defective
3 (Internal disconnection, V06 (male) Resistance value
short-circuiting or Between (1) and (2) 20 – 60 z
grounding fault)
Presumed cause and
Assembled-type diode position during troubleshooting.

4 D04 defective
D02 (male) Resistance value (Continuitiy)
Between (3) and (7) Above 1 Mz (No continuitiy)
Disconnection of wiring Wiring harness between FB1-2 outlet and M38 (male) Resistance
harness Below 1 z
(1) value
5 (Disconnection or
defective contact with Wiring harness between M38 (male) (2), J07 and V06 Resistance
Below 1 z
Resistance
Wiring harness between V06 (female) (1) and grounding Below 1 z
value
Grounding fault of wiring Between wiring harness between FB1-2 outlet and M38
Resistance
harness (male) (1) or between FB1-2 outlet and related circuits Above 1 Mz
6 value
(Contact with grounding and grounding
circuit) Between wiring harness between M38 (male) (2), J07
Resistance
and V06 (female) (2) or between M38 (male) (2) and Above 1 Mz
value
20-516 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-8
E-8 Attachment circuit does not change

When attachment is installed
(1) When working mode A or E is selected, attachment circuit is not

Failure • Attachment circuit does not switched to crusher circuit (reciprocation circuit).
information change. (2) When working mode B is selected, attachment circuit is not
switched to breaker circuit (one-way circuit).
• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or discon-
Relative
nection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected,
information
however.

Attachment return selec- position during the troubleshooting.
tor solenoid defective V12 (male) Resistance value
1
(Internal disconnection
or short-circuit) Between (1) and (2) 20 – 60 z
Attachment return selec- position during the troubleshooting.
tor relay defective R20 (male) Resistance value

Presumed cause and
2
or short-circuit) Between (3) and (5) Below 1 z
Between (3) and (6) Above 1 Mz
Disconnection of wiring Wiring harness between J03 (male) (8) and R20 Resistance
harness Below 1 z
(female) (3) value
3 (Disconnection or
defective contact with Wiring harness between R20 (female) (5) and V12 Resistance
Below 1 z
Wiring harness between C03 (female) (3), (13), (23) Resistance
Below 1 z
Short-circuit of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the ON
4
(Contact with 24 V Between wiring harness and R20 (female) (5) and V12
PC400/450(LC)-7 20-517
(1)
TROUBLESHOOTING E-8
Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
20-518 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-9
E-9 No display in monitor panel at all
Failure • No display in monitor panel at all.

information When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative
—
information

If the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in
1 Fuse No. 12 fault
the circuit. (See Cause 3.)
harness Wiring harness from P01 (female) (1) (2) to J07 to FB1- Resistance
2 Below 1 z
(Disconnection or defect 12 value
contact with connector) Wiring harness from P01 (female) (6) (7) to J04 and Resistance
Presumed cause and
Below 1 z
grounding value
3 (Contact with grounding
(GND) Between wiring harness from P01 (female) (1) (2) to Resistance Above
circuit) J07 to FB1-12 outlet or related circuits and grounding value 1 Mz
Voltage and resistance
P01 Starting switch
Monitor panel value
4
controller defective Between (1) (2) and
ON Voltage: 20 – 30 V
grounding
Between (6) (7) and Resistance value: Below
OFF
grounding 1z
Electrical Circuit Diagram for Power Source in Monitor Panel
PC400/450(LC)-7 20-519
(1)
TROUBLESHOOTING E-10, E-11
E-10 Part of display on monitor panel is missing
Failure Part of the display in the monitor panel is missing during

• Part of display on monitor panel is missing
information starting switch in ON.
Relative
—
information

Presumed cause and
a Turn the starting switch ON during the troubleshooting.
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen
1 Monitor panel LCD fault
becomes totally white) by the following switching operation, then the monitor panel is
normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
E-11 Monitor panel displays contents irrelevant to the model
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

Presumed cause and
a Turn the starting switch in ON during the troubleshooting (monitoring).
Model code signal fault Monitoring code Item Normal display

1
(Internal failure) 00200 Controller model code PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
20-520 PC400/450(LC)-7
(1)
TROUBLESHOOTING E-10, E-11
E-12 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lights up while the engine was running.
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No.: 04200 Fuel level sensor)

Fuel level lowered (sys-
1 a Check fuel level in fuel tank. If insufficient, refill fuel.
tem in normal condition)
Fuel level sensor fault
2 (Internal A60 (male) Fuel level Resistance value

Presumed cause and
disconnection) Between (1) and ground- FULL (Upper limit) Approx. 12 z

ing EMPTY (Lower limit) 85 – 110 z
(GND) Wiring harness between P02 (female) (2) and A60 Resistance
Below 1 z
circuit) (female) (1) value
Monitor panal P02 (female) Fuel level Resistance value
4
defective
Between (2) and FULL (Upper limit) Approx. 12 z
grounding EMPTY (Lower limit) 85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC400/450(LC)-7 20-521
(1)
TROUBLESHOOTING E-13
E-13 Engine water temperature gauge does not display correctly

(1) While the engine water temperature rises normally,
the temperature gauge does not rise above the white
Failure • Engine water temperature gauge does not range (C).
information display correctly (2) While the engine water temperature is stabilized
normally, the temperature gauge rises up to the red
range (H).
• The signal of the engine water high temperature sensor for the water temperature gauge is received
from the engine controller through the communication line.
• If the engine water high temperature sensor system becomes defective, error code [E934] may be dis-
Relative
played.
information
• Input from the engine water high temperature sensor (voltage and temperature) can be checked in the
monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water tempera-
ture (High temperature))

Engine water high a Turn the engine starting switch OFF for the preparations, and turn to ON or keep
temperature sensor the engine running during the troubleshooting.
defective TWH (male) Resistance value
1
(Internal disconnection,
short-circuiting or Between (1) and (2) 3.5 k – 90 kz
grounding fault) Between (1), (2) and grounding Above 1 Mz
harness
Wiring harness between CB2 (female) (27) and TWH Resistance
(female) (1) value

Wiring harness between CB2 (female) (29), (39) and Resistance
Presumed cause and
connector) Below 1 z
TWH (female) (2) value
3
circuit) Above 1 Mz
TWH (female) (1) and grounding value
4 harness
(Contact with 24 V circuit) Between wiring harness between CB2 (female) (27) and
Voltage Below 1 V
TWH (female) (1) and grounding
5
defective
Between (27), (29) and (39) 3.5 k – 90 kz
If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble
is in the monitor panel, troubleshooting cannot be carried out.)
20-522 PC400/450(LC)-7
(1)
Electrical circuit diagram related to engine water high temperature sensor
PC400/450(LC)-7 20-523
(1)
E-14 Hydraulic oil temperature gauge does not display correctly
• Hydraulic oil temperature gauge does not display correctly

Failure
(1) Hydraulic oil temperature rises normally, but the display does not rise from the white range (C).
information
(2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No.: 04401 Hydraulic oil temperature)

Hydraulic oil temperature Engine cooling water
sensor fault A61 Resistance value
1 temperature
or short-circuiting) Between (1) and (2) 90 – 3.5 kz
Between (2) and ground- 10 – 100 °C
Above 1 Mz
ing
harness
(female) (2) value
Presumed cause and

connector) Wiring harness between P02 (female) (13) and A61 Resistance
Below 1 z
(female) (1) value
3
(GND) circuit) A61 (female) (2) and grounding value 1 Mz
4
(Contact with 24 V Between wiring harness between P02 (female) (12) and
A61 (female) (2) and grounding
Engine cooling water
Monitor panal P02 Resistance value
5 temperature
defective
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100 °C
90 – 3.5 kz
grounding
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
20-524 PC400/450(LC)-7
(1)
E-15 Fuel gauge does not display correctly
• Fuel gauge does not display correctly

Failure
(1) Though fuel was refilled, the display does not exceed the red range (E).
information
(2) Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No.: 04200 Fuel sensor voltage)

Fuel level sensor fault
1 (Internal disconnection A60 (male) Fuel level Resistance value
or short-circuiting) Between (1) and FULL (Upper limit) Approx. 12 z
grounding EMPTY (Lower limit) 85 – 110 z
2 (Disconnection or
Presumed cause and
defective contact with Below 1 z

3
(GND) circuit) A60 (female) (1) and grounding value 1 Mz
4
(Contact with 24 V Between wiring harness between P02 (female) (2) and
A60 (female) (1) and grounding
Monitor panal P01 Fuel level Resistance value
5
defective
Between (2) and ground- FULL (Upper limit) Approx. 12 z
ing EMPTY (Lower limit) 85 – 110 z
Electrical Circuit Diagram for Fuel Level Sensor
PC400/450(LC)-7 20-525
(1)
E-16 Swing lock monitor does not display correctly
(1) Though the swing lock switch was turned ON, the
Failure swing lock monitor does not light up.
• Swing lock monitor does not display correctly
information (2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.

Swing lock switch position during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
1
short-circuiting) OFF Above 1 Mz
Between (1) and (2)
ON Below 1 z
harness
Wiring harness from P02 (female) (17) to J02 and X05 Resistance
(male) (1) value

Presumed cause and
connector) Wiring harness from X05 (male) (2) to J05 and Resistance
Below 1 z
grounding value
harness
3 Between wiring harness from P02 (female) (17) to J02
(Contact with grounding Resistance
(GND) circuit) and X05 (male) (1), or between P02 (female) (17) to Above 1 Mz
value
C02 (female) (38) and grounding
4 harness Between wiring harness from P02 (female) (17) to J02
(Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to Voltage Below 1 V
C02 (female) (38) and grounding
5 Monitor panel defective P02 Swing lock switch Voltage
20-526 PC400/450(LC)-7
(1)
Electrical circuit diagram related to swing holding brake solenoid
PC400/450(LC)-7 20-527
(1)
E-17 When monitor switch is operated, nothing is displayed
Failure • When monitor switch is operated, nothing is dis- (1) When mode selector switch is operated, working
information played. mode monitor is not displayed.
Relative
—
information

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure • When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is oper-
information displayed. ated, mode selection screen is not displayed.
Relative
—
information

cause and
(3) When selector switch is operated, flow rate

Failure • When monitor switch is operated, nothing is
adjustment screen or flow rate selection screen
information displayed.
is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (4) When maintenance switch is operated, item
information displayed. selection screen is not displayed.
Relative
—
information

cause and
Failure • When monitor switch is operated, nothing is (5) When automatic deceleration switch is operated,
information displayed. automatic deceleration monitor is not displayed.
Relative
• When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.
information

cause and
20-528 PC400/450(LC)-7
(1)
Failure • When monitor switch is operated, nothing is (6) When travel speed selector switch is operated,
information displayed. travel speed monitor is not displayed.
Relative
• When the travel speed does not change either, conduct the troubleshooting for H-22.
information

cause and
Failure • When monitor switch is operated, nothing is (7) When wiper switch is operated, wiper monitor is
information displayed. not displayed.
Relative
• When the wiper does not operate either, conduct the troubleshooting for E-18.
information

cause and
PC400/450(LC)-7 20-529
(1)
E-18 Windshield wiper and window washer do not work
Failure • Windshield wiper and window washer do not

(1) The windshield wiper does not work.
information work.
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

Window rear limit switch position during the troubleshooting.
fault W03 (female) Front window Resistance value
1
or short-circuiting) When installed at front Above 1 Mz
Between (1) and (2)
When retracted at rear Below 1 z
Windshield wiper motor position during the troubleshooting.
2 fault
W04 (male) Continuity and resistance value
Between (3) and (1) Continued
harness
Wiring harness between P01 (female) (9) and W04 Resistance
Presumed cause and
(female) (3) value
connector) Wiring harness between P01 (female) (10) and W04 Resistance
Below 1 z
(female) (1) value
4
(GND) circuit) W03 (2) value 1 Mz
Monitor panel fault
(Window rear limit switch P02 Front window Voltage
system) Between (15) and ground- When installed at front 20 – 30 V
ing When retracted at rear Below 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Monitor panel fault P01 Windshield wiper switch Resistance value
(Windshield wiper motor Between (9) and OFF Below 3 V
system) grounding
Between (10) and Below 3 V 20 – 30 V
ON
grounding (Constant cycle)
20-530 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
PC400/450(LC)-7 20-531
(1)
Failure • Windshield wiper and window washer do not

(2) Windshield washer does not operate.
information work.
Relative
—
information

1 Fuse No. 4 defective If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.)
Washer motor defective
2 (Internal disconnection A50 (male) Resistance value
harness
Wiring harness from FB1-4 to J03 to J06 and A50 Resistance
Presumed cause and
(female) (1) value
connector) Wiring harness from A50 (female) (2) to J04 and P01 Resistance
Below 1 z
(female) (3) value
Grounding fault of wiring Between wiring harness from FB1-4 to J03 to J06 and
Resistance Above
harness A50 (female) (1), or FB1-4 to D02 (female) (4), and to
4 value 1 Mz
(Contact with grounding other relative circuits and grounding
circuit) Between wiring harness from A50 (female) (2) to J04
Resistance Above
and P01 (female) (3), or A50 (female) (2) to D02
value 1 Mz
Monitor panel P01 Windshield washer switch Voltage
5
defective
20-532 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Window Washer Motor
PC400/450(LC)-7 20-533
(1)
E-19 Alarm buzzer cannot be cancelled
Failure
• The alarm buzzer cannot be cancelled.
information
Relative • Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function.

Alarm buzzer stop switch Alarm buzzer
1 defective P03 (female) Resistance value
stop switch
Release Above 1 Mz
Between (1) and (2)
Depress Below 1 z
Presumed cause and

harness
Wiring harness between P02 (female) (16) and P03 Resistance
(male) (1) value
Wiring harness from P03 (male) (2) to J05 to grounding Below 1 z
value
3 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (16) and
Voltage Below 1 V
P03 (male) (1) and grounding
4 Monitor panel defective P02 Alarm buzzer stop switch Voltage
Between (16) and Release 20 – 30 V
grounding Depress Below 1 V
Electrical circuit diagram related to alarm buzzer stop switch
20-534 PC400/450(LC)-7
(1)
E-20 “Boom RAISE” is not correctly displayed in monitor function
Failure • “Boom RAISE” is not correctly displayed in monitor function

information “Boom RAISE” is not correctly displayed in the monitor function on the monitor panel.
Relative
—
information

Boom RAISE PPC
hydraulic switch fault R.H. work equipment
1 S06 (male) Resistance value
(Internal disconnection control lever
or short-circuiting) NEUTRAL Above 1 Mz
Between (1) and (2)
Boom RAISE Below 1 z
harness
(female) (2) value

Presumed cause and
connector) Wiring harness between S06 (female) (1) and Resistance

Below 1 z
grounding value
(GND) Between wiring harness between C03 (female) (10) and Resistance Above
circuit) S06 (female) (2) and grounding value 1 Mz
4
a Turn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
Pump controller R.H. work equipment
5 C03 Voltage
Between (10) and NEUTRAL 20 – 30 V
grounding Boom RAISE Below 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC400/450(LC)-7 20-535
(1)
E-21 “Boom LOWER” is not correctly displayed in monitor function
Failure • “Boom LOWER” is not correctly displayed in monitor function

information “Boom LOWER” is not correctly displayed in the monitor function on the monitor panel.
Relative
—
information

Boom LOWER PPC
Between (1) and (2)
Boom LOWER Below 1 z
harness
(female) (2) value
Presumed cause and

connector) Wiring harness between S02 (female) (1) and ground- Resistance
Below 1 z
ing value
3
(GND) circuit) S02 (female) (2) and grounding value 1 Mz
4
(Contact with 24 V cir- Between wiring harness between C03 (female) (20) and
cuit) Voltage Below 1 V
5 C03 Voltage
Between (20) and ground- NEUTRAL 20 – 30 V
ing Boom LOWER Below 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-536 PC400/450(LC)-7
(1)
E-22 “Arm IN” is not displayed normally in monitoring function
Failure • “Arm IN” is not displayed normally in monitoring “Arm IN” is not displayed normally in monitoring
information function. function (special function) of monitor panel.
Relative
information

Presumed cause and
Arm IN PPC pressure The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for
1
sensor defective error code [E247].
Pump controller If cause 1 is not the cause of the trouble, the pump controller may be defective
2
defective (Troubleshooting cannot be carried out since the defect is in the pump controller).
PC400/450(LC)-7 20-537
(1)
E-23 “Arm DUMPING” is not correctly displayed in monitor function
• “Arm DUMPING” is not correctly displayed in monitor function

Failure
“Arm DUMPING” is not correctly displayed in the monitor function (special function) on the monitor
information
panel.
Relative
—
information

Arm DUMPING PPC
hydraulic switch defect L.H. work equipment
and short-circuiting) NEUTRAL Above 1 Mz
Between (1) and (2)
Arm DUMPING Below 1 z
harness
(female) (2) value
Presumed cause and

Below 1 z
grounding value
3
4
Pump controller L.H. work equipment
5 C03 Voltage
ing Arm DUMPING Below 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-538 PC400/450(LC)-7
(1)
E-24 “Bucket CURL” is not displayed normally in monitoring function
“Bucket CURL” is not displayed normally in

Failure • “Bucket CURL” is not displayed normally in
monitoring function (special function) of monitor
information monitoring function.
panel.
Relative
information

Presumed cause and
Bucket CURL PPC pres- The bucket CURL PPC pressure sensor may be defective. Carry out troubleshoot-
1
sure sensor defective ing for error code [E248].
Pump controller If cause 1 is not the cause of the trouble, the pump controller may be defective
2
defective (Troubleshooting cannot be carried out since the defect is in the pump controller).
PC400/450(LC)-7 20-539
(1)
E-25 “Bucket DUMPING” is not correctly displayed in monitor function
• “Bucket DUMPING” is not correctly displayed in monitor function

Failure
“Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the monitor
information
panel.
Relative
—
information

Bucket DUMPING PPC
and short-circuiting) NEUTRAL Above 1 Mz
Between (1) and (2)
Bucket DUMPING Below 1 z
harness
(female) (2) value
Presumed cause and

Below 1 z
grounding value
3
4
5 C03 Voltage
grounding Bucket DUMPING Below 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-540 PC400/450(LC)-7
(1)
E-26 “Swing” is not displayed normally in monitoring function
Failure • “Swing” is not displayed normally in monitor- “Swing” is not displayed normally in monitoring
information ing function. function (special function) of monitor panel.
Relative
information

Swing left PPC pressure
switch defective Left work equipment
(Internal disconnection or control lever
short-circuit) Neutral Min. 1 Mz
Between (1) and (2)
Left swing position Max. 1 z
Swing right PPC pres-
sure switch defective Left work equipment
(Internal disconnection or control lever
short-circuit) Neutral Min. 1 Mz
Between (1) and (2)
Right swing position Max. 1 z
Presumed cause and
Max. 1 z
harness (female) (2) or S03 (female) (2) value
3
(Disconnection or defective Resistance
contact with connector) Wiring harness between S07 (female) (1) and grounding Max. 1 z
value
Resistance
Wiring harness between S03 (female) (1) and grounding Max. 1 z
value
4
circuit) Min. 1 Mz
S07 (female) (2) or S03 (female) (2) and grounding value
5 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (29) and Voltage Max. 1 V
S07 (female) (2) or S03 (female) (2) and grounding
Left work equipment
control lever
Between (29) and ground- Neutral 20 – 30 V
ing Left or right swing position Max. 1 V
20-542 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC400/450(LC)-7 20-543
(1)
E-27 “TRAVEL” is not correctly displayed in monitor function
Failure • “TRAVEL” is not correctly displayed in monitor function

information “TRAVEL” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
—
information

Travel PPC hydraulic running during the troubleshooting.
switch fault S30 (male) Travel control lever Resistance value
1
Between (1) and (2)
Forward or reverse Below 1 z
harness
Wiring harness from C03 (female) (39) to J01 to S30 Resistance
(female) (2) value

Presumed cause and
connector) Wiring harness from S30 (female) (1) to J05 to ground- Resistance
Below 1 z
ing value
harness
3 Wiring harness from C03 (female) (39) to J01 to S30
(Contact with grounding Resistance Above
(GND) circuit) (female) (2), or between wiring harness between C03
value 1 Mz
(female) (39) and A43 (female) (2) and grounding
harness
4 Wiring harness from C03 (female) (39) to J01 to S30
(Contact with 24 V
circuit) (female) (2), or between wiring harness between C03 Voltage Below 1 V
(female) (39) and A43 (female) (2) and grounding
Pump controller C03 Travel control lever Voltage
5
defective
grounding Forward or backward Below 1 V
20-544 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC400/450(LC)-7 20-545
(1)
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function
• “Travel Differential Pressure” is not correctly displayed in monitor function

Failure
“Travel Differential Pressure” is not correctly displayed in the monitor function (special function) on the
information
monitor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the
information travel differential mechanism is turned ON.

Travel steering PPC
hydraulic switch fault S31 (male) Travel control lever Resistance value
1
(Internal disconnection NEUTRAL Above 1 Mz
or short-circuiting) Between (1) and (2) One side of right or left
Below 1 z
only
harness
(female) (2) value
Presumed cause and

connector) Wiring harness from S31 (female) (1) to J05 to Resistance
Below 1 z
grounding value
3
4
Pump controller C02 Travel control lever Voltage
5
defective NEUTRAL 20 – 30 V
Between (16) and ground-
ing One side of right or left
Below 1 V
only
20-546 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC400/450(LC)-7 20-547
(1)
E-29 “Service” is not correctly displayed in monitor function
Failure • “Service” is not correctly displayed in monitor function

information “Service” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
—
information

Service (front) PPC running during the troubleshooting.
hydraulic switch fault S10 (male) Service pedal Resistance value
1
Between (1) and (2)
Operated to front Below 1 z
Service (rear) PPC running during the troubleshooting.
hydraulic switch fault S11 (male) Service pedal Resistance value
2
Between (1) and (2)
Operated to rear Below 1 z

Presumed cause and
harness Wiring harness between C02 (female) (35) and S10

Resistance
3 (Disconnection or (female) (2), or wiring harness between C02 (female) Below 1 z
value
defective contact with (35) and S11 (female) (2)
connector) Wiring harness between S10 (female) (1) and ground- Resistance
Below 1 z
ing value
4 (Contact with grounding Wiring harness between C02 (female) (35) and S10
(GND) Resistance Above
(female) (2), or between wiring harness between C02
circuit) value 1 Mz
(female) (35) and S11 (female) (2) and grounding
harness
5 Wiring harness between C02 (female) (35) and S10
(Contact with 24 V
circuit) (female) (2), or between wiring harness between C02 Voltage Below 1 V
(female) (35) and S11 (female) (2) and grounding
6 Pump controller defective C02 Service pedal Voltage
ing Operated to front or rear Below 1 V
20-548 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC400/450(LC)-7 20-549
(1)
E-30 Travel alarm does not sound or does not stop sounding
• Travel alarm does not sound or does not stop sounding.

Failure
(1) The travel alarm does not sound while the machine is traveling.
information
(2) The alarm begins to sound when the machine is at a standstill.
Relative
—
information

When fuse No.15 is blown, there is a big possibility that grounding fault occurred in
1 Fuse No. 15 fault
the circuit. (See Cause 4.)
a Start the engine during the troubleshooting (monitoring).
Control lever operated:
2 Travel signal fault ON
01900 Travel
Control lever NEUTRAL:
OFF
Presumed cause and
If the monitor display is not correct, proceed to No. E-29 Troubleshooting.

harness
Wiring harness between FB1-15 outlet to J03 and A43 Resistance
(female) (1) value
Wiring harness between A43 (female) (2) and J01 (19) Below 1 z
value
harness Between wiring harness between FB1-15 outlet to J03
4
(Contact with grounding and A43 (female) (1), or between wiring harness Resistance Above
(GND) circuit) between FB1-15 outlet and other related circuit and value 1 Mz
grounding
As this is an internal failure, troubleshooting cannot be conducted. (If none of the
5 Travel alarm fault causes listed in Item 1 through 4 above is found, the travel alarm is judged as
defective)
20-550 PC400/450(LC)-7
(1)
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC400/450(LC)-7 20-551
(1)
E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
Troubleshooting procedure for air conditioner system

a The control panel of the air conditioner constantly monitors the sensors and other devices in the system .
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to
the procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice

a Check the “Self-diagnosis notice” on the control
panel according to the following procedure.
• How to display “Self-diagnosis notice”

1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the “Self-diagnosis notice” displayed
on display monitor (2).
• How to select “Self-diagnosis notice” Self-diagnosis

Failure mode
If multiple “Self-diagnosis notices” are recorded, notice
press the UP switch ( ) or DOWN switch ( ) E-- No failures
of temperature setting switch (3) to select Disconnection in recirculated air
E11
another notice. sensor
E12 Short-circuit in recirculated air sensor
• How to delete “Self-diagnosis notice” E15
Disconnection in water temperature
When reproducing the “Self-diagnosis notices” sensor
or after removing the cause of a failure, press E16
Short-circuit in water temperature
the switches on both sides of recirc/fresh air sensor
selector switch (4) simultaneously for 3 seconds E18 Short-circuit in daylight sensor
or more, and all the “Self-diagnosis notices” are E43 Abnormality in air outlet damper
deleted. E44 Abnormality in air mix damper
Abnormality in recirculated and fresh
• Finishing display of “Self-diagnosis notice” E45
air damper
To finish display of the “Self-diagnosis notice”,
press OFF switch (1) or turn the starting switch
OFF.
20-552 PC400/450(LC)-7
(1)
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
• Disconnection in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Action of • When the following condition is satisfied, the operation returns to normalcy.
control panel <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting

Defective recirculated
standard value in normal state
starting switch ON.

1 air sensor
THI (male) Resistance
Possible causes and
Between (1) and (2) 300 z – 430 kz
Disconnection of wiring starting switch ON.
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
2 Resistance Max. 1 z
or defective contact with (female) (2)
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
Defective air conditioner If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
3
system may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12
Contents of
• Short circuit in the recirculated air sensor system is detected.
trouble
• Fixes the recirculated air temperature for control.
Related
information

Defective recirculated air
starting switch ON.

1 sensor (Internal short cir-
THI (male) Resistance
Possible causes and
cuit)
Between (1) and (2) 300 z – 430 kz
harness (Disconnection Wiring harness between M30 (female) (12) and TH I
connector) Wiring harness between M29 (female) (11) and TH I
Resistance Max. 1 z
(female) (1)
3
PC400/450(LC)-7 20-553
(1)
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
• Disconnection in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal dis-
THW (male) Resistance
Possible causes and
connection)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16
Contents of
• Short circuit in the water temperature sensor system is detected.
trouble
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
Related
information

Defective water tempera-
starting switch ON.

1 ture sensor (Internal
THW (male) Resistance
Possible causes and
short circuit)
Between (1) and (2) 95 z – 455 kz
harness (Disconnection Wiring harness between M30 (female) (14) and THW
connector) Wiring harness between M29 (female) (11) and THW
Resistance Max. 1 z
(female) (1)
3
20-554 PC400/450(LC)-7
(1)
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
• Short circuit in the daylight sensor system is detected.
trouble
• Assumes that the daylight sensor is not installed for control.
Related
information

Defective daylight sen-

1 The daylight sensor may be defective. Check it directly.
sor (Internal short circuit)
Possible causes and
harness (Disconnection Wiring harness between M30 (female) (16) and P15
connector) Wiring harness between M30 (female) (3) and P15
Resistance Max. 1 z
(female) (1)
3
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
• Abnormality in air outlet servomotor system is detected.
trouble
• Stops the air outlet servomotor.
control panel • <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
Related a Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
information the motor output shaft and break the motor coils.

Defective air outlet servo-
1 The air outlet servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MV1 (female) (1) and M30
Possible causes and
Resistance Max. 1 z
(female) (3)
Disconnection in wiring Wiring harness between MV1 (female) (3) and M29
harness (Disconnection Resistance Max. 1 z
(female) (11)
2 in wiring harness or
defective contact in con- Wiring harness between MV1 (female) (5) and M30
Resistance Max. 1 z
nector) (female) (9)
Resistance Max. 1 z
(female) (8)
Resistance Max. 1 z
(female) (9)
Defective air conditioner If none of causes 1 and 2 is the cause of the trouble, the air conditioner system may
3
system be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400/450(LC)-7 20-555
(1)
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
• Abnormality in air mix servomotor system is detected.
trouble
• Stops the air mix servomotor.

Defective air mix servo-
1 The air mix servomotor may be defective. Check it directly.
motor (Internal defect)
starting switch ON.

Wiring harness between MAM (female) (1) and M29
Possible causes and
Resistance Max. 1 z
(female) (11)
Disconnection in wiring Wiring harness between MAM (female) (3) and M30
(female) (3)
defective contact in con- Wiring harness between MAM (female) (5) and M30
Resistance Max. 1 z
Resistance Max. 1 z
(female) (4)
Resistance Max. 1 z
(female) (5)
3
20-556 PC400/450(LC)-7
(1)
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
• Abnormality in recirculated and fresh air servomotor system is detected.
trouble
• Stops the recirculated and fresh air servomotor.

Defective recirculated
1 and fresh air servomotor The recirculated and fresh air servomotor may be defective. Check it directly.
(Internal defect)
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
2 Defective fuse (in unit)
Possible causes and
Check the related circuits.

starting switch ON.
Disconnection in wiring Wiring harness between MRF (female) (1) and M29
(female) (6)
defective contact in con- Wiring harness between MRF (female) (3) and M29
Resistance Max. 1 z
Wiring harness between MRF (female) (7), fuse in unit,
Resistance Max. 1 z
and M33 (female) (3)
Defective air conditioner If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be
4
system defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
PC400/450(LC)-7 20-557
(1)
Electrical Circuit Diagram for Air Conditioner
20-558 PC400/450(LC)-7
(9)
Troubleshooting by failure phenomenon
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information

1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.)
starting switch ON.
Wiring harness between fuse 11 outlet and M33 (male)
Disconnection in wiring Resistance Max. 1z
(3)
harness (Disconnection
Wiring harness between M27 (female) (14) and M30
2 in wiring harness or Resistance Max. 1z
(female) (6)
defective contact in con-
nector) Wiring harness between M33 (male) (2) and chassis
Resistance Max. 1z
ground
Wiring harness between M29 (female) (12) and chassis
Resistance Max. 1z
ground
Possible causes and
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between circuit breaker fuse 11
3 Resistance Min. 1 Mz
(Contact with ground cir- outlet and M33 (male) (3) and chassis ground
cuit) Between wiring harness between M27 (female) (14) and
M30 (female) (6) and chassis ground
troubleshooting.
Defective air conditioner M33 Voltage
4
unit Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
troubleshooting.
M30, M29 Voltage
5 Defective control panel
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
PC400/450(LC)-7 20-559
(1)
Trouble • The air conditioner does not operate. (2) Air does not come out (Air flow is insufficient).
Related
information

Defective blower relay starting switch ON.
2
(on coil side) R30 (male) Resistance
Between (1) and (3) 140 – 340 z
troubleshooting.
Defective blower relay
3 R30 Fan switch Voltage
(on contact side)
Between (4) and
ON (Operated) 20 – 30 V
chassis ground
Defective power transis- troubleshooting.
4
tor (Internal defect) Fan switch If air flow can be changed with fan switch,
Operate in range of Low, Medium, and High power transistor is normal.
troubleshooting.
Possible causes and
Defective blower motor MB (female) Fan switch Voltage

5
(Internal defect) Between (1) and (2) ON (Operated) 20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
starting switch ON.
Wiring harness between fuse 11 outlet, fuse in unit, R30
Resistance Max. 1 z
(3), R31 (female) (1), and M30 (female) (6)
Wiring harness between M29 (female) (3) and R30
Resistance Max. 1 z
(female) (1)
Disconnection in wiring Resistance Max. 1 z
ground
harness (Disconnection
Wiring harness between MB (female) (1) and R30
6 in wiring harness or Resistance Max. 1 z
(female) (4)
defective contact in con-
nector) Wiring harness between MB (female) (2) and PTR
Resistance Max. 1 z
(female) (3)
Wiring harness between PTR (female) (1) and chassis
Resistance Max. 1 z
ground
Wiring harness between PTR (female) (2) and M30
Resistance Max. 1 z
(female) (7)
Wiring harness between PTR (female) (4) and M30
Resistance Max. 1 z
(female) (8)
7
20-560 PC400/450(LC)-7
(1)
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information

Defective compressor starting switch ON.
2
relay (on coil side) R31 (male) Resistance
Between (1) and (2) 140 – 340 z
troubleshooting (Setting of temperature: Highest cooling position).
Defective compressor
3 R31 Fan switch Voltage
relay (on contact side)
Between (4) and chassis
ON (Operated) 20 – 30 V
ground
Defective thermostat
4 The thermostat may be defective. Check it directly.
(Internal defect)
Defective high/low pres- starting switch ON.
5 sure switch (Internal dis-

P17 (male) Resistance
connection)
Possible causes and
Between (1) and (2) Max. 1 z

6 The compressor clutch may be defective. Check it directly.
clutch (Internal defect)
7 The compressor may be defective. Check it directly.
(Internal defect)
starting switch ON.
Wiring harness between M30 (female) (4) and P17
Resistance Max. 1 z
(female) (1)
Wiring harness between P17 (female) (2) and chassis
Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between fuse 11 outlet, R31 (female)
(2), fuse in unit, R31 (female) (1), and M30 (female) (6)
defective contact in con- Wiring harness between ST1 (female) (1) and R31
Resistance Max. 1 z
Wiring harness between M29 (female) (2) and ST1
Resistance Max. 1 z
(female) (2)
Resistance Max. 1 z
ground
Wiring harness between R31 (female) (4) and M34
Resistance Max. 1 z
(female) (1)
9
PC400/450(LC)-7 20-561
(1)
Electrical Circuit Diagram for Air Conditioner
20-562 PC400/450(LC)-7
(1)
TROUBLESHOOTING OF HYDRAULIC
AND MECHANICAL SYSTEM (H MODE)
system chart for hydraulic and mechanical system .................................................................................... 20-602

H-1 All work equipment lack power, or travel and swing speeds are slow.................................................. 20-605
H-2 Engine speed sharply drops or engine stalls ....................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................... 20-607
H-4 Abnormal noise is heard from around hydraulic pump......................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................... 20-608
H-6 Fine control mode does not function .................................................................................................... 20-608
H-7 Boom moves slowly or lacks power ..................................................................................................... 20-609
H-8 Arm moves slowly or lacks power ........................................................................................................ 20-610
H-9 Bucket moves slowly or lacks power.................................................................................................... 20- 611
H-10 Work equipment does not move in its single operation...................................................................... 20- 611
H-11 Work equipment has a bit too fast hydraulic drift................................................................................ 20-612
H-12 Work equipment has big time lag ....................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit................................................................ 20-613
H-14 One-touch power max. function does not work .................................................................................. 20-613
H-15 Machine push-up function does not work........................................................................................... 20-614
H-16 In compound operation, work equipment with larger load moves slowly ........................................... 20-615
H-17 In swing + boom RAISE operation, boom moves slowly.................................................................... 20-615
H-18 In swing + travel, travel speed drops sharply ..................................................................................... 20-615
H-19 Machine swerves in travel .................................................................................................................. 20-616
H-20 Machine travels slowly ....................................................................................................................... 20-617
H-21 Machine cannot be easily steered or lacks power ............................................................................. 20-618
H-22 Travel speed does not shift, or it is slower or faster than preset speed. ............................................ 20-619
H-23 Track shoe does not turn (on one side only) ...................................................................................... 20-620
H-24 Machine does not swing..................................................................................................................... 20-621
H-25 Swing acceleration is poor, or swing speed is slow ........................................................................... 20-622
H-26 Excessive overrun when stopping swing ........................................................................................... 20-623
H-27 There is big shock when stopping swing............................................................................................ 20-624
H-28 There is big abnormal noise caused when stopping swing ................................................................ 20-624
H-29 Swing natural drift is too big ............................................................................................................... 20-625
H-30 Attachment circuit does not change ................................................................................................... 20-626
H-31 Flow rate in attachment circuit cannot be adjusted ............................................................................ 20-626
PC400/450(LC)-7 20-601
(1)
BEFORE TROUBLESHOOTING FOR HYDRAULIC
TROUBLESHOOTING AND MECHANICAL SYSTEMS (H MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM
20-602 PC400/450(LC)-7
(1)
BEFORE TROUBLESHOOTING FOR HYDRAULIC
TROUBLESHOOTING AND MECHANICAL SYSTEMS (H MODE)
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 systems.
PC400/450(LC)-7 20-603
(1)

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting
1
Presumed cause and
2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge “good” or “no good” about pre-
3
filing and reference sumed causes.
purpose only. It does not • References for making judgement of “good” or “no good”
stand for any priority)
4
20-604 PC400/450(LC)-7
(1)
TROUBLESHOOTING H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information • All the work equipment lack power, or their travel and swing speeds are slow.
Relative information • Set the working mode at A mode for troubleshooting.

a Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of unload Control lever Unload pressure
1
valve 4.12 ± 1.0 MPa
All control levers in NEUTRAL
{42 ± 10kg/cm2}
Control lever Main relief pressure
Improper adjustment or 33.34 – 36.77 MPa
2 malfunctioning of main Arm, DIGGING
{340 – 375kg/cm2}
relief valve
If the pressure does not return to normalcy even after the adjustment, malfunctioning
of main relief valve or its internal failure is suspected. In that case, check the valve
itself.
Malfunctioning of
Control lever Control circuit source pressure
3 self pressure
decompression valve 2.84 – 3.43 MPa
{29 – 35kg/cm2}
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Presumed cause and
Improper adjustment or Pump delivery pressure 1

4 malfunctioning of PC Swing lock: ON
Arm: Digging relief Approx. 0.6
valve PC valve output pressure
(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment,
malfunctioning of PC valve or its internal failure is suspected. In that case, check the
valve itself.
Travel speed Travel control lever LS-EPC output pressure
Malfunctioning of
5 Approx. 1.37 MPa
LS-EPC valve Lo NEUTRAL
{Approx. 14 kg/cm2}
Hi OPERATED 0 MPa {0 kg/cm2}
Oil pressure ratio
Oil pressure to be mea- Travel without load (con-
sured All control levers in
trol lever held at half
NEUTRAL
Improper adjustment or stroke)
6 malfunctioning of LS Pump delivery pressure 1
valve Nearly equal pressure Approx. 0.6
LS valve output pressure
(Approx. 3/5)
malfunctioning of LS valve or its internal failure is suspected. In that case, check the
valve itself.
Malfunctioning of servo
7 Malfunctioning of servo piston is suspected. Check the piston itself.
piston
If none of the above listed causes is detected, the piston pump is suspected of
8 Piston pump defective
deteriorated performance, malfunctioning or internal failure.
PC400/450(LC)-7 20-605
(1)
TROUBLESHOOTING H-2
H-2 Engine speed sharply drops or engine stalls
Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Relative Information

Control lever Main relief pressure
Improper adjustment or 33.34 – 36.77 MPa
1 malfunctioning of main Arm, DIGGING
{340 – 375kg/cm2}
relief valve
malfunctioning of the main relief valve or its internal failure is suspected. In that
case, check the valve itself.
Oil pressure to be
Measurement condition Oil pressure ratio
measured
Improper adjustment or Pump delivery pressure 1
Swing lock: ON
2 malfunctioning of PC Approx. 0.6

Arm: Digging relief
Presumed cause and
valve PC valve output pressure

(Approx. 3/5)
malfunctioning of the PC valve or its internal failure is suspected. In that case, check
the valve itself.
Oil pressure ratio
Oil pressure to be Travel without load
measured All control levers in
(control lever held at half
NEUTRAL
valve Nearly equal pressure Approx. 0.6
(Approx. 3/5)
malfunctioning of the LS valve or its internal failure is suspected. In that case, check
the valve itself.
Orifice or filter in servo The orifice or filter in the pump servo equipment is suspected of clogging. Check the
4
equipment clogged equipment itself.
Malfunction of servo
5 The servo piston is suspected of malfunction. Check the piston itself.
piston
20-606 PC400/450(LC)-7
(1)
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel or swing move
Failure information • No work equipment nor travel and swing functions can be set in motion.
Relative information • Set the working mode at A mode for the troubleshooting.

Safety lock lever Solenoid output pressure
Malfunctioning of PPC
1 Locked 0 MPa {0 kg/cm2}
lock solenoid valve
2.84 – 3.43 MPa

Presumed cause and
Released
{29 – 35kg/cm2}
Malfunctioning of
2 self pressure
All control levers in NEUTRAL position
{29 – 35kg/cm2}
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in
the following manner.
3 Piston pump defective
• Remove the main oil pressure measurement plug and crank the engine. If oil flows
out, it is in normal condition.
It is presumed that the pump shaft does not rotate due to some internal failure of the
4 Damper defective
damper. Check the damper itself.
H-4 Abnormal noise is heard from around hydraulic pump
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —
Hydraulic oil level

1 Make a visual check.
lowered
Presumed cause and
Quality of hydraulic oil

2 Air may have get mixed with the oil. Make a visual check.
bad
Hydraulic tank cap It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
breather clogged causing negative pressure inside the tank. Make a visual check.
Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.
5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.
PC400/450(LC)-7 20-607
(1)
H-5 Auto-decelerator does not work
Failure information • The auto-decelerator does not work.

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
Relative information
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

Presumed cause and

Travel control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Malfunctioning of travel
1
PPC valve (shuttle valve)
Above 2.75 MPa
Operation
{Above 28 kg/cm2}
H-6 Fine control mode does not function
Failure information • The fine control mode poorly functions or its response is slow.

LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of LS- pressure
1
EPC valve Approx. 1.37 MPa
Lo NEUTRAL
{Approx. 14 kg/cm2}
Hi OPERATED 0 MPa {0 kg/cm2}
Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
Presumed cause and
clogged
Oil pressure ratio
Oil pressure to be Travel without load
measured All control levers in
NEUTRAL
valve Nearly equal oil pressure Approx. 0.6
PC valve output pressure
(Approx. 3/5)
malfunctioning of the LS valve or its internal failure is suspected. In that case, check
the valve itself.
Malfunctioning of servo
4 Malfunctioning of the servo piston is suspected. Check the piston itself.
piston
20-608 PC400/450(LC)-7
(1)
TROUBLESHOOTING H-7
H-7 Boom moves slowly or lacks power
Failure information • The boom moves slowly or lacks power


Malfunctioning of right R.H. work equipment control lever PPC valve output pressure
1 PPC valve NEUTRAL 0 MPa {0 kg/cm2}
(in boom circuit)
Boom RAISE Above 2.75 MPa
Boom LOWER {Above 28 kg/cm2}
Travel lever Solenoid output pressure
Malfunction of merge/
2 Neutral 0 MPa {0 kg/cm2}
divide solenoid valve
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
Malfunctioning of merge/
The merge/divide valve of control valve (main and LS valves) is presumed to
3 divide valve (main and
malfunction. Check the valve itself.
LS valves)
Malfunctioning of boom The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check the
4
control valve (spool) valve itself.
Malfunctioning of boom
The pressure compensation valve in the boom control valve (Lo • Hi) is presumed to
5 control valve (pressure
Presumed cause and

compensation valve)
The regeneration valve in the boom control valve (Lo) or the seal is presumed to
6 control valve
(regeneration valve)
Malfunctioning of boom The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the
7
control valve (lock valve) valve itself.
Malfunction of boom con- The check valve in the boom control valve (Hi) is presumed to malfunction. Check
8
trol valve (check valve) the valve itself.
Malfunctioning of safety
The safety valve for the lock valve is presumed to malfunction, or the seal is
9 valve for lock valve or
suspected to be defective. Check the valve itself.
seal defective
The suction valve (bottom side) in the boom control valve (Lo) is presumed to
10 control valve (suction
malfunction, or the seal is suspected to be defective.
valve) or seal defective
The safety and suction valves (head side) in the boom control valve (Lo) are
control valve (safety and
11 presumed to malfunction, or the seal is suspected to be defective. Check those
suction valves) or seal
valves themselves.
defective
Malfunctioning of LS
shuttle valve (left travel, LS shuttle valves in the left travel control valve, bucket control valve and service
12
bucket and service control valve are presumed to malfunction. Check those valves themselves.
valves)
13 Boom cylinder defective Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
PC400/450(LC)-7 20-609
(1)
TROUBLESHOOTING H-8
H-8 Arm moves slowly or lacks power
Failure information • The arm moves slowly, or lacks power.


L.H. work equipment control lever PPC valve output pressure
Malfunctioning of left
1 NEUTRAL 0 MPa {0 kg/cm2}
PPC valve (arm circuit)
Arm DIGGING Above 2.75 MPa
Arm DUMPING {Above 28 kg/cm2}
Travel lever Solenoid output pressure
2 Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
The merge/divide valve of control valve (main and LS valves) is presumed to
3 divide valve (main and
LS valves)
Presumed cause and
Malfunctioning of arm The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the
4
control valve (spool) valve itself.
Malfunctioning of arm
The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to
compensation valve)
The generation valve in the arm control valve (Lo) is presumed to malfunction, or the
6 control valve
seal is suspected to be defective. Check the valve itself.
(regeneration valve)
control valve (safety and The safety and suction valves in the arm control valve (Lo • Hi) are presumed to
7
suction valves) or seal malfunction, or the seal is suspected of defect. Check those valves themselves.
defective
Malfunction of arm control The quick return valve in the arm control valve (Hi) is presumed to malfunction.
8
valve (quick return valve) Check the valve itself.
LS shuttle valves in the right travel control valve, boom control valve, left travel
shuttle valve (right travel,
9 control valve, bucket control valve and service valve are presumed to malfunction.
boom, left travel, bucket
Check those valves themselves.
and service valves)
10 Arm cylinder defective Arm cylinder Amount oil leakage from cylinder
Digging relief 20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
20-610 PC400/450(LC)-7
(1)
H-9 Bucket moves slowly or lacks power
Failure information • The bucket moves slowly, or lacks power.


Malfunctioning of right R.H. work equipment control lever PPC valve output pressure
1 PPC valve NEUTRAL 0 MPa {0 kg/cm2}
(bucket circuit)
Bucket DIGGING Above 2.75 MPa
Bucket DUMPING {Above 28 kg/cm2}
Malfunctioning of bucket The spool in the bucket control valve is presumed to malfunction. Check the valve
Presumed cause and
2
control valve (spool) itself.
Malfunctioning of bucket
The pressure compensation valve in the bucket control valve is presumed to
compensation valve)
Malfunctioning of bucket
The safety and suction valves in the bucket control valve are presumed to
control valve (safety and
4 malfunction, or the seal is suspected to be defective. Check those valves
suction valves) or seal
themselves.
defective
Malfunction of LS shut- The LS shuttle valve in the service control valve is presumed to malfunction. Check
5
tle valve (service valve) the valve itself.
6 Bucket cylinder defective Bucket cylinder Amount oil leakage from cylinder
H-10 Work equipment does not move in its single operation
• Work equipment does not move in its single operation

(1) The boom does not move when operated independently.
Failure information (2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.
(4) Bottom dump does not move singly. (For loading shovel)


Presumed cause and
Work equipment control lever PPC valve output pressure

Malfunctioning of PPC
valve
Above 2.75 MPa
Operated
{Above 28 kg/cm2}
Malfunctioning of work
The spool in the work equipment control valve is presumed to malfunction. Check
2 equipment control valve
the valve itself.
(spool)
PC400/450(LC)-7 20-611
(9)
TROUBLESHOOTING H-11
H-11 Work equipment has a bit too fast hydraulic drift
• Work equipment has a bit too fast hydraulic drift

Failure information
(1) Hydraulic drift of the boom is a bit too fast.

Presumed cause and

1 Boom cylinder defective Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
Boom control lever (lock The seal at lock valve in the boom control lever is suspected to be defective. Check
2
valve) seal defective the valve itself.
Seal at safety valve for The seal at the safety valve in the lock valve (Lo) is suspected to be defective.
3
lock valve defective Check the valve itself.

Failure information
(2) Hydraulic drift of the arm is a bit too fast.

1 Arm cylinder defective Arm cylinder Amount oil leakage from cylinder
Presumed cause and

The seal for safety and suction valves (bottom side) in the arm control valve (Lo • Hi)
Arm control valve (safety
is suspected to be defective. Check the valve itself.
2 and suction valves) seal
(Whether the seal is defective or not may well be determined by changing for other
defective
safety and suction valves.)
Arm control valve (spool) The seal for spool in the arm control valve (Lo • Hi) is suspected to be defective.
3
seal defective Check the seal itself.
Arm control valve
The seal for pressure compensation valve (bottom side) in the arm control valve
4 (pressure compensation
(Lo • Hi) is suspected to be defective. Check the seal itself.
valve) seal defective

Failure information
(3) Hydraulic drift of the bucket is a bit too fast.

1 Bucket cylinder defective Bucket cylinder Amount oil leakage from cylinder
Presumed cause and

The seal for the safety and suction valves (bottom side) in the bucket control lever is
Bucket control valve
suspected to be defective. Check the seal itself.
2 (safety and suction
(Whether the seal is defective or not may well be determined by changing for other
valves) seal defective
safety and suction valves.)
Bucket control valve The seal for spool in the bucket control valve is suspected to be defective. Check the
3
(spool) seal defective seal itself.
Bucket control valve
The seal for pressure compensation valve (bottom side) in the bucket control valve is
suspected to be defective. Check the seal itself.
valve) seal defective
20-612 PC400/450(LC)-7
(1)
TROUBLESHOOTING H-12, H-13, H-14
H-12 Work equipment has big time lag
Failure information • The work equipment has a big time lag.


LS-EPC valve output
Malfunctioning of pressure
1
LS-EPC valve Approx. 1.37 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Presumed cause and
Hi Operation 0 MPa {0 kg/cm2}

Malfunctioning of control
valve (regeneration The regeneration valve in the control valve is presumed to malfunction. Check the
2
valve) - with boom and valve itself.
arm only
The safety and suction valves (boom : head side, arm and bucket : bottom side) of
Malfunctioning of control the control valve are presumed to malfunction. Check those valves themselves
3 valves (safety & suction directly.
valve) (Whether they are defective or not may well be determined by changing them for
other safety and suction valves.)
Malfunctioning of control
The pressure compensation valve of the control valve is presumed to malfunction.
4 valve (pressure
Check the valve itself directly.
compensation valve)
H-13 Other work equipment moves when relieving single circuit
Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.

Presumed cause and
Control valve (pressure

The seal for pressure compression valve in the control valve is suspected to be
1 compensation valve)
defective. Check the seal itself.
seal defective
H-14 One-touch power max. function does not work
Failure information • One-touch power max. function does not work.


Presumed cause and

Swing lock switch Solenoid valve output pressure
Malfunctioning of
1 OFF 0 MPa {0 kg/cm2}
2-stage solenoid valve
2.84 – 3.43 MPa
ON
{29 – 35kg/cm2}
Malfunctioning of main The main relief valve of control valve is presumed to malfunction. Check the valve
2
relief valve itself.
PC400/450(LC)-7 20-613
(1)
H-15 Machine push-up function does not work
Failure information • The machine push-up function does not work

Relative information • When carrying out troubleshooting, set the working mode in A-mode.

a Prepare with starting switch OFF, then run engine at high idling and carry out
Presumed cause and
troubleshooting.
Malfunction of machine Machine push-up switch Solenoid outlet pressure
1
push-up solenoid valve
OFF Min. 2.75 MPa {Min. 28 kg/cm3}
ON 0 MPa {0 kg/cm2}
Malfunction of boom
The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting
2 control valve
side on the head side) may be malfunctioning. Check it directly.
(safety-suction valve)
20-614 PC400/450(LC)-7
(1)
TROUBLESHOOTING H-16, H-17, H-18
H-16 In compound operation, work equipment with larger load moves slowly
Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —

The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.
Combination of compound Work equipment with Work equipment with
operation larger load smaller load

Presumed cause and
Boom RAISE +
Boom Arm
Malfunctioning of arm DIGGING
pressure compensation Boom RAISE +
1 Arm Boom
valve for work equipment arm DUMPING
with larger load Boom RAISE +
Boom Bucket
bucket DIGGING
Arm DUMPING +
Arm Bucket
bucket DIGGING
Boom LOWER +
Arm Boom
arm DUMPING
H-17 In swing + boom RAISE operation, boom moves slowly
Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

Presumed cause and
The LS select valve of control valve is presumed to malfunction, or the seal is
1 select valve or seal
suspected to be defective. Check the valve and seal themselves.
defective
H-18 In swing + travel, travel speed drops sharply
Failure information • In a compound operation of swing + travel, the travel speed drops sharply.
Relative information • If the travel speed is slow in the single operation of travel, carry out the H-20 check first.

Presumed cause and
The LS shuttle valve in the left travel control valve or the swing control valve is
1 shuttle valve (left travel
presumed to malfunction. Check both of them directly.
and swing)
PC400/450(LC)-7 20-615
(1)
H-19 Machine swerves in travel
Failure information • The machine tends to swerve while traveling.


Malfunctioning of travel Operated to Forward Above 2.75 MPa
1
PPC valve Operated to Reverse {Above 28 kg/cm2}
Differential output between right
0.4 MPa {4 kg/cm2}
and left sides
Malfunctioning of
2 self-pressure
{29 – 35 kg/cm2}
Oil Pressure ratio
Oil pressure to be
Travel without load

Improper adjustment or measured All control levers in
Presumed cause and
3 malfunctioning of LS NEUTRAL
stroke)
valve
Pump delivery pressure 1
Nearly equal pressure Approx. 0.6
(Approx. 3/5)
Malfunctioning of travel Travel control lever PPC valve output pressure
4 interlocking solenoid NEUTRAL 0 MPa {0 kg/cm2}
valve
2.84 – 3.43 MPa
Operating one side only
{29 – 35 kg/cm2}
Malfunctioning of travel The travel interlocking valve of control valve is presumed to malfunction. Check the
5
interlocking valve valve itself.
Malfunctioning of travel The spool in the travel interlocking valve is presumed to malfunction. Check the
6
control valve (spool) spool itself.
Malfunction of travel
7 Travel control lever Amount of oil leakage from travel motor
motor
Travel relief 40 l/min
The final drive is suspected of an internal failure. Check the inside of the final drive
directly.
8 Final drive defective
(An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.)
20-616 PC400/450(LC)-7
(1)
H-20 Machine travels slowly
Failure information a The machine's travel speed is slow.

Relative information a Set the working mode at A mode for the troubleshooting.

Malfunctioning of travel Operated to Forward Above 2.75 MPa
1
PPC valve Operated to Reverse {Above 28 kg/cm2}
Output differential between right and left Below 0.4 MPa
or front and rear {Below 4 kg/cm2}
Malfunctioning of
2 self-pressure
{29 – 35kg/cm2}
LS-EPC valve output

Malfunctioning of pressure
Presumed cause and
3
LS-EPC valve Approx. 1.37 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Hi Operated 0 MPa {0 kg/cm2}
Malfunction of travel The spool in the travel control valve is presumed to malfunction. Check the spool
4
The pressure compensation valve in the travel control valve is presumed to
compensation valve)
The suction valve in the travel control valve is presumed to malfunction. Check the
valve itself.
valve)
Malfunctioning of LS The LS shuttle valve in the bucket control valve is presumed to malfunction. Check
7
shuttle valve (bucket) the valve itself.
Malfunction of travel
7 Travel control lever Amount of oil leakage from travel motor
motor
directly.
(An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.)
PC400/450(LC)-7 20-617
(1)
H-21 Machine cannot be easily steered or lacks power
Failure information • The machine cannot be easily steered.


Malfunctioning of travel Travel control lever PPC valve output pressure (steering)
1 PPC valve (steering NEUTRAL on both sides 0 MPa {0 kg/cm2}
spool)
Above 2.75 MPa
{Above 28 kg/cm2}
Malfunctioning of travel Travel control lever Solenoid valve output pressure
2 interlocking solenoid NEUTRAL 0 MPa {0 kg/cm2}
valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Malfunctioning of travel The travel interlocking valve of control valve is presumed to malfunction. Check the
3
interlocking valve valve itself.
Travel control lever Solenoid valve output pressure

Presumed cause and
2.84 – 3.43 MPa

OPERATED
{29 – 35 kg/cm2}
Malfunctioning of merge/ The merge/divide valve of control valve is presumed to malfunction. Check the valve
5
divide valve itself.
Malfunction of travel The spool in the travel control valve is presumed to malfunction. Check the spool
6
The pressure compensation valve in the travel control valve is presumed to
compensation valve)
The suction valve in the travel control valve is presumed to malfunction. Check the
valve itself.
valve)
Malfunctioning of LS The LS shuttle valve in the bucket control valve is presumed to malfunction. Check
9
shuttle valve (bucket) the valve itself.
Check valve seal
The seal in the check valve of LS oil pressure pick-up port is suspected to be
10 defective at LS oil
defective. Check the seal itself.
pressure pick-up port
The seal in the check valve of the travel motor is suspected to be defective. Check
Malfunctioning of travel the seal itself.
11
motor (safety valve) (Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.)
The seal in the check valve of the travel motor is suspected of defect. Check the seal
Malfunctioning of travel itself.
12
motor (check valve) (Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.)
20-618 PC400/450(LC)-7
(1)
H-22 Travel speed does not shift, or it is slower or faster than preset speed.
Failure information • Travel speed does not shift, or it is slower or faster than preset speed.

Travel speed Travel control lever Monitoring [01500]
Lo Fine control 690 mA
Mi (to the extent that the 740 mA
Hi decelerator is released) 0 mA
Malfunctioning of
1 a Stop engine for preparations. Start troubleshooting at engine high idling.

LS-EPC valve
Presumed cause and
LS-EPC valve output

pressure
Approx. 1.37 MPa
Lo NEUTRAL
{approx. 14 kg/cm2}
Hi Operation 0 MPa {0 kg/cm2}
Solenoid output
Malfunctioning of travel pressure
2
speed solenoid valve Lo NEUTRAL 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operation
{29 – 35 kg/cm2}
Malfunctioning of travel The travel motor is presumed to malfunction when shifting speed. Check the speed
3
motor (speed shifting) shifting portion directly.
PC400/450(LC)-7 20-619
(1)
H-23 Track shoe does not turn (on one side only)
Failure information • A track shoe does not turn (only on one side).

Travel control valve (suc- The suction valve seat in the travel control valve is suspected of defect. Check the
1
tion valve) seat defective seat itself.
Travel motor (safety

2 The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
Presumed cause and
valve) seat defective

Travel motor (check
3 The check valve seat in the travel motor is suspected of defect. Check the seat itself.
valve) seat defective
4 Travel Motor speed Travel control lever Amount of oil leakage from travel motor
directly.
(A failure inside the final drive may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained oil.)
20-620 PC400/450(LC)-7
(1)
H-24 Machine does not swing
• Machine does not swing

Failure information
(1) The machine swings neither to the right nor to the left.

Malfunctioning of swing R.H. work equipment control lever Solenoid valve output pressure
1 holding brake solenoid
valve NEUTRAL 0 MPa {0 kg/cm2}
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Malfunctioning of swing The parking brake portion of the swing motor is presumed to malfunction.
2
motor (holding brake) Check it directly.

Presumed cause and
L.H. work equipment

Swing lock switch Swing relief pressure
control lever
Improper adjustment or
3 malfunctioning of swing 27.95 – 32.85 MPa
ON Swing relief
motor (safety valve) {285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the
valve itself.
4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below 11 l/min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
Swing machinery
5 (A failure inside the swing machinery may well be determined by an abnormal noise
defective
from within, abnormal heat generated or metal dust or chips contained in the drained
oil.)
• Machine does not swing

Failure information
(2) The machine does not swing in one direction.

Malfunctioning of swing L.H. work equipment control lever PPC valve output pressure
1
PPC valve NEUTRAL 0 MPa {0 kg/cm2}

Presumed cause and
Swing operated Above 2.75 MPa {Above 28 kg/cm2}

Malfunctioning of swing The spool in the swing control valve is presumed to malfunction. Check the spool
2
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction seal itself.
3
valve) seal defective (Whether the seal is defective or not may well be determined by swapping the right
and left suction valves and watching if there is any change.)
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check seal itself.
4
and left check valves and watching the result.)
PC400/450(LC)-7 20-621
(1)
H-25 Swing acceleration is poor, or swing speed is slow
• Swing acceleration is poor, or swing speed is slow

Failure information
(1) Swing acceleration is poor, or swing speed is slow.

The LS shuttle valves for all the control valves are presumed to malfunction. Check
1 shuttle valve
them directly.
(all LS shuttles)
Malfunctioning of swing The swing holding brake portion of the swing motor is presumed to malfunction.
2
motor (holding brake) Check it directly.

Presumed cause and
L.H. work equipment

control lever
ON Swing relief
valve itself.
Inside of the swing machinery is presumed to malfunction. Check itself.
Swing machinery
5 (Whether it is defective or not may well be determined by abnormal noise, abnormal
defective
generation of heat and the mixture of the metal particles in drain oil.)
• Swing acceleration is poor, or swing speed is slow

Failure information
(2) Swing acceleration is poor only on one side, or swing speed is slow.

1
Presumed cause and
Malfunctioning of swing The spool in the swing control valve is presumed to malfunction. Check the valve
2
Malfunctioning of swing
The pressure compensation valve in the swing motor is presumed to malfunction.
Check the valve itself.
compensation valve)
4
and left suction valves and watching the result.)
5
20-622 PC400/450(LC)-7
(1)
H-26 Excessive overrun when stopping swing
• Excessive overrun when stopping swing

Failure information
(1) The work equipment overruns excessively when stopping swing.

L.H. work equipment

Presumed cause and
control lever
ON Swing relief
valve itself.
• Excessive overrun when stopping swing

Failure information
(2) Swing acceleration is poor only on one side, or swing speed is slow.

1
Presumed cause and
The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return
2 (Whether the valve is clogged or not may well be determined by swapping the right
valve clogged
and left valves and watching the result.)
Malfunctioning of swing The spool in the swing control valve is resumed to malfunction. Check the valve
3
4
and left suction valves and watching the result.)
5
PC400/450(LC)-7 20-623
(1)
H-27 There is big shock when stopping swing
Failure information • There is a big shock caused when stopping a swing motion.


Presumed cause and
1
The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
2 (Whether the valve malfunctions or not may well be determined by swapping the
PPC slow return valve
right and left valves and watching the result.)
3 The swing motor shockless valve is presumed to malfunction. Check the valve itself.
motor (shockless valve)
H-28 There is big abnormal noise caused when stopping swing
Failure information • There is a big abnormal noise caused when stopping a swing motion.

Malfunctioning of
1 The backpressure valve is presumed to malfunction. Check the valve itself.
backpressure valve
Malfunction of swing The safety valve in the swing motor is presumed to malfunction. Check the valve
Presumed cause and
2
motor (safety valve) itself.
The seal in suction valve of the swing motor is suspected of defect. Check the seal
Malfunction of swing itself.
3
motor (suction valve) (Whether the seal is defective or not may well be determined by swapping the right
and left valves and watching the result.)
The swing machinery is suspected of an internal failure. Check the inside of the
machinery itself.
Swing machinery
4 (A failure inside the swing machinery may well be determined by monitoring
defective
abnormal noise, abnormal heat generated or metal dust or chips contained in the
drained oil.)
20-624 PC400/450(LC)-7
(1)
H-29 Swing natural drift is too big
• Swing natural drift is too big.

Failure information
(1) When the swing holding brake is activated.
• When the swing lock switch is ON position, or the swing holding brake release switch is in the
Relative information normal position, the swing brake is activated and the swing is fixed with a disc brake.
• Set the working mode in A mode for troubleshooting.

Presumed cause and

Swing and holding brake R.H. work equipment control lever Solenoid valve output pressure
1 solenoid valve
malfunctioned NEUTRAL 0 MPa {0 kg/cm2}
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
Swing motor (parking
The parking portion of the swing motor is suspected of malfunctioning and interior
2 brake portion)
failure. Check that portion directly.
malfunctioned
• Swing natural drift is too big.

Failure information
(2) When the swing holding brake is released.
• When the swing holding brake release switch is in the emergency condition, the swing brake is
Relative information released and the swing is retained only hydraulically.
• Set the working mode in A mode for troubleshooting.

Swing control valve The seal in the spool of the swing control valve is suspected of defect. Check the
1
(spool) malfunctioned spool itself directly.
Swing control valve

The pressure compensation valve seal in the swing control valve is suspected of
Presumed cause and
defect. Check the valve itself directly.

valve) malfunctioned
Swing motor (safety The safety valve seal in the swing motor is suspected of defect. Check the valve
3
valve) defective itself directly.
Swing motor (suction The suction valve seal in the swing motor is suspected of defect. Check the valve
4
Swing motor (check The check valve seal in the swing motor is suspected of defect. Check the valve
5
Swing motor (shockless
The shockless valve in the swing motor is suspected of malfunction or the seal is
6 valve) malfunctioned or
suspected of defect. Check the valve or seal itself directly.
seal defective
PC400/450(LC)-7 20-625
(1)
H-30 Attachment circuit does not change
Failure information • The return circuit of the attachment circuit does not change.
• If an attachment is installed, the service circuit changes according to the selected working mode
as shown below.
1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low
pressure.
2) In mode B: The single acting circuit is selected and the safety valve is set to the high
pressure.
* Setting of the safety valve on only port B side is changed. Port A is always set to the low
pressure.

a Keep the engine stopped for the preparations, and keep it running at high idling
Malfunction of Working mode Solenoid valve output pressure

Presumed cause and
1 attachment return
selector solenoid valve Mode E or A 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Mode B
{29 – 35 kg/cm2}
Malfunction of
2 attachment return The attachment return selector valve may have a malfunction. Check it directly.
selector valve
Malfunction of service
The safety valve of the service control valve (on port B side) may have a
3 control valve (safety
malfunction. Check it directly.
valve)
H-31 Flow rate in attachment circuit cannot be adjusted
Failure information • Flow rate in attachment circuit cannot be adjusted.

• If an attachment is installed, the flow rate in the service circuit changes according to the
selected working mode.
• How to adjust the flow rate in modes A and E is different from that in mode B. For details, see
OPERATION MANUAL.

Malfunction of
The attachment flow rate adjustment EPC valve may have a malfunction. Check it
1 attachment flow rate
Presumed cause and
directly.
adjustment EPC valve
a Keep the engine stopped for the preparations, and keep it running at high idling
PPC valve output
Malfunction of service Wiring harness connector Service pedal
2 pressure
PPC valve
Disconnect connector V30 In NEUTRAL 0 MPa {0 kg/cm2}
of attachment flow rate Above 2.75 MPa
adjustment EPC valve. Operated
{Above 28 kg/cm2}
20-626 PC400/450(LC)-7
(1)
TROUBLESHOOTING OF ENGINE
(S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702

METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703
S-1 Starting performance is poor (starting always takes time).................................................................... 20-706
S-2 Engine does not start ........................................................................................................................... 20-707
S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710
S-4 Engine stops during operations ............................................................................................................ 20- 711
S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712
S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716
S-10 Fuel consumption is excessive........................................................................................................... 20-717
S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719
S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720
S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721
S-15 Abnormal noise is made..................................................................................................................... 20-722
S-16 Vibration is excessive ......................................................................................................................... 20-723
PC400/450(LC)-7 20-701
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be disassem- 4) Other maintenance items can be checked
bled. externally, so check any item that is consid-
• It will become impossible to find the cause of ered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out troubleshoot- judge whether to handle it as a real failure or as
ing, it is necessary to carry out thorough prior a problem with the method of operation, etc.
investigation and to carry out troubleshooting in a When operating the machine to re-enact the
accordance with the fixed procedure. troubleshooting symptoms, do not carry out
any investigation or measurement that may
2. Points to ask user or operator make the problem worse.
1) Have any other problems occurred apart
from the problem that has been reported? 5. Troubleshooting
2) Was there anything strange about the Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d
machine before the failure occurred? inspection in Items 2 – 4 to narrow down the
3) Did the failure occur suddenly, or were there causes of failure, then use the troubleshooting
problems with the machine condition before matrix or flowchart to locate the position of the
this? failure exactly.
4) Under what conditions did the failure occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before the as follows.
failure? When were these repairs carried 1) Start from the simple points.
out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
6. Measures to remove root cause of failure

Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root cause.
20-702 PC400/450(LC)-7
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections + in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information that he has obtained from the
user and the results of that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high prob-
ability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
PC400/450(LC)-7 20-703
(1)
<Example of troubleshooting> Exhaust smoke is black
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
20-704 PC400/450(LC)-7
(1)
PC400/450(LC)-7 20-705
(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
a With the common rail fuel injection system, the

fuel injection timing is recognized electrically, so
even when the starting operation is carried out,
the engine may not start until the crankshaft has
completed two rotations. However, this does
not indicate any abnormality.
20-706 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-2
S-2 Engine does not start
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations”.
• Defective electrical system
• Failure on chassis side
PC400/450(LC)-7 20-707
(1)
TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
20-708 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out
but engine does not start
• Lack of rotating force due to defective electrical
system
PC400/450(LC)-7 20-709
(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly

20-710 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops

• Internal part of engine seized
• Failure on chassis side
PC400/450(LC)-7 20-711
(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
20-712 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output

PC400/450(LC)-7 20-713
(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• There is excessive fuel.
20-714 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes con-
tinuous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
PC400/450(LC)-7 20-715
(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
20-716 PC400/450(LC)-7
(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
PC400/450(LC)-7 20-717
(1)
S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
20-718 PC400/450(LC)-7
(1)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
PC400/450(LC)-7 20-719
(1)
S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out troubleshooting

for “Oil is in cooling water”.
20-720 PC400/450(LC)-7
(1)
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise of hydraulic oil temperature on chassis side
PC400/450(LC)-7 20-721
(1)
S-15 Abnormal noise is made
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the engine
sound becomes slightly louder because it is operated in the
low temperature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration
mode and the engine noise is higher for 3 seconds, but this
is not an abnormality.
20-722 PC400/450(LC)-7
(1)
S-16 Vibration is excessive
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry

out troubleshooting also for “Abnormal noise is made”.
PC400/450(LC)-7 20-723
(1)
30 DISASSEMBLY AND
ASSEMBLY
HOW TO READ THIS MANUAL.................... 30- 2 DISASSEMBLY AND ASSEMBLY OF

PRECAUTIONS WHEN PERFORMING RECOIL SPRING ASSEMBLY................. 30- 69
OPERATION ............................................30- 4 EXPANSION AND INSTALLATION OF TRACK
SPECIAL TOOL LIST .................................... 30- 6 SHOE ASSEMBLY................................... 30- 71
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF AIR
CYLINDER HEAD ASSEMBLY ................ 30- 13 CONDITIONER UNIT ASSEMBLY .......... 30- 73
REMOVAL AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF
REAR SEAL ............................................. 30- 20 OPERATOR’S CAB ................................. 30- 75
REMOVAL AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF
FRONT SEAL...........................................30- 24 MONITOR ASSEMBLY............................ 30- 78
REMOVAL AND INSTALLATION OF FUEL REMOVAL AND INSTALLATION OF PUMP
SUPPLY PUMP ASSEMBLY.................... 30- 27 CONTROLLER ........................................ 30- 79
REMOVAL AND INSTALLATION OF FUEL REMOVAL AND INSTALLATION OF ENGINE
INJECTOR ASSEMBLY ...........................30- 30 CONTROLLER ........................................ 30- 80
REMOVAL AND INSTALLATION OF REMOVAL AND INSTALLATION OF
NOZZLE TIP ............................................30- 33 REVOLVING FRAME ASSEMBLY .......... 30- 81
STARTING MOTOR ASSEMBLY ............. 30- 35 COUNTERWEIGHT ASSEMBLY............. 30- 84
RADIATOR ASSEMBLY...........................30- 36 HYDRAULIC TANK ASSEMBLY.............. 30- 85
HYDRAULIC OIL COOLER ASSEMBLY .30- 38 HYDRAULIC PUMP ASSEMBLY............. 30- 87
REMOVAL AND INSTALLATION OF ENGINE REMOVAL AND INSTALLATION OF OIL SEAL
AND HYDRAULIC PUMP ASSEMBLY .... 30- 40 IN HYDRAULIC PUMP INPUT SHAFT ... 30- 90
REMOVAL AND INSTALLATION OF SWING REMOVAL AND INSTALLATION OF
CIRCLE ASSEMBLY................................ 30- 45 CONTROL VALVE ASSEMBLY ............... 30- 91
REMOVAL AND INSTALLATION OF SWING DISASSEMBLY AND ASSEMBLY OF
MOTOR AND SWING MACHINERY CONTROL VALVE ASSEMBLY ............... 30- 94
ASSEMBLY .............................................. 30- 46 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF SWING CENTER SWIVEL JOINT ASSEMBLY .... 30- 98
MOTOR AND SWING MACHINERY DISASSEMBLY AND ASSEMBLY OF
ASSEMBLY .............................................. 30- 47 CENTER SWIVEL JOINT ASSEMBLY .... 30-100
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF WORK
SPROCKET ............................................. 30- 54 EQUIPMENT PPC VELVE ASSEMBLY... 30-101
REMOVAL AND INSTALLATION OF DISASSEMBLY AND ASSEMBLY OF
TRAVEL MOTOR AND FINAL DRIVE TRAVEL PPC VALVE ASSEMBLY........... 30-102
ASSEMBLY .............................................. 30- 55 DISASSEMBLY AND ASSEMBLY OF
DISASSEMBLY AND ASSEMBLY OF FINAL HYDRAULIC CYLINDER ASSEMBLY..... 30-103
DRIVE ASSEMBLY ..................................30- 56 REMOVAL AND INSTALLATION OF WORK
DISASSEMBLY AND ASSEMBLY OF EQUIPMENT ASSEMBLY ....................... 30-108
CARRIER ROLLER ASSEMBLY ............. 30- 63 REMOVAL AND INSTALLATION OF
DISASSEMBLY AND ASSEMBLY OF TRACK OPERATOR’S CAB GLASS
ROLLER ASSEMBLY...............................30- 65 (STUCK GLASS) ..................................... 30- 111
DISASSEMBLY AND ASSEMBLY OF IDLER REMOVAL AND INSTALLATION OF FRONT
ASSEMBLY .............................................. 30- 66 WINDOW ASSEMBLY ............................. 30-121
PC400/450(LC)-7 30-1
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q:Special tools which are very useful if stand for the following.
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly a This mark gives guidance or precau-
developed for this model.
2 This mark stands for a specific coating
tions when doing the procedure.
R: Tools with upgraded part numbers,
remodeled from already available tools
3 This mark indicates the specified
agent to be used.
for other models.
Blank: Tools already available for other mod-
5
torque.
els, used without any modification. This mark indicates an amount of oil or
3) Circle mark (Q) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T means • Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
30-2 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY

• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
2 This mark stands for a specific coating

mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools
3 This mark indicates the specified
agent to be used.
N: Tools with new part numbers, newly
developed for this model.
5
torque.
R: Tools with upgraded part numbers,
This mark indicates an amount of oil or
remodeled from already available tools
water to be added.
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
SKETCHES OF SPECIAL TOOLS
3) Circle mark (Q) in sketch column: • Various special tools are illustrated for the con-
A circle mark means that a sketch of the venience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
PC400/450(LC)-7 30-3
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
PRECAUTIONS WHEN PERFORMING OPERATION

Be sure to follow the general precautions given below when performing removal or installation (disassembly or
assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it properly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake during assembly.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wir-
ing, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Install the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
Taper 1/8
12 07049-01215 12 10 15
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22 L
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 DEW00401
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it
securely.
• When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1) Start the engine and run it at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the
cylinders 100 mm from the end of their stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified
level. Run the engine to circulate the coolant water through the system. Then check the coolant water level
again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed for repair, bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
PC400/450(LC)-7 30-5
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t............Cannot be substituted, must always be installed (used)

q............Extremely useful if available or can be substituted with commercially available part
a New/Remodel: N............Tools with new part numbers, newly developed for this model
R: ...........Tools with upgraded part numbers, remodeled from items already available for oth-
er models
Blank: ....Tools already available for other models, can be used 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).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
Removal, installation of noz-

1 795-799-1170 Puller t 1
zle holder assembly
Tightening of cylinder head
2 790-331-1110 Wrench q 1
bolt
3 795-931-1100 Seal puller t 1 Removal of engine seal
795-931-1210 Push tool t 1
4 • 01050-31625 • Bolt t 3
Press fitting of engine rear
• 01050-31645 • Bolt t 3
seal
795-931-1220 Push tool t 1
5
• 01050-31645 • Bolt t 3
795T-521-1140 Push tool t 1 Q
Engine assembly A
• 790-101-5221 • Grip t 1 Press fitting of engine front
6
• 01010-81225 • Bolt t 1 seal
• 01050-31640 • Bolt t 3
795-471-1800 Remover t 1 N
• 795-471-1810 • Plate t 1
• 795-471-1820 • Bolt t 1
7 Removal of fuel supply pump
• 795-471-1830 • Bracket t 1
• 01435-01035 • Bolt t 3
• 01435-01025 • Bolt t 1
Removal, installation of noz-
8 795T-471-1550 Wrench t 1 Q
zle tip
Removal, installation of
Engine and B 796T-601-1110 Stopper t 1 N Q
engine mounting bolt
hydraulic pump
796-460-1210 Oil stopper q 1
assembly C Stopping of oil
796-770-1320 Adapter q 1
30-6 PC400/450(LC)-7
(5)
New/remodel
Necessity
Symbol
Sketch
Q'ty
1 796T-627-1630 Push tool q 1 Q Removal of shaft

2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
790-101-5401 Push tool kit t 1
• 790-101-5531 • Plate 1
Swing motor and 4 Press fitting of oil seal
swing machinery D • 790-101-5421 • Grip 1
assembly • 01010-51240 • Bolt 1
Press fitting of bearing inner
5 790-201-2870 Push tool t 1
race
Press fitting of bearing inner
6 790-201-2770 Push tool t 1
race
7 796T-626-1110 Push tool t 1 Q Press fitting of bearing
796-627-1210 Wrench assembly t 1
• 796-627-1220 • Wrench 1 Removal, installation of
1
• 796-427-1140 • Pin 3 round nut
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
Final drive assem- 791-122-1130 Plate q 1
E
bly 790-101-2550 Leg q 2
Pressing of bearing inner
2 790-101-2740 Adapter q 2
race
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 t}) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1 Installation of floating seal
Carrier roller 791-430-3230 Installer t 1
F
assembly 791-601-1000 Oil pump t 1
Track roller 791-630-1780 Installer t 1
G Supply of oil
assembly 791-601-1000 Oil pump t 1
791-575-1520 Installer t 1
Idler assembly H
791-601-1000 Oil pump t 1
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
Disassembly, assembly of
1 Cylinder
790-101-1600 t 1 recoil spring assembly
(686 kN {70 t})
Recoil spring 790-101-1102 Pump t 1
J
assembly
• 790-201-1660 • Plate 1
2 Installation of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
PC400/450(LC)-7 30-7
(5)
New/remodel
Necessity
Symbol
Sketch
Q'ty
Remover and
791-650-3000 t 1
installer
Track shoe
K Cylinder Pulling out of master pin
assembly 790-101-1300 t 1
(980 kN {100 t})
790-101-1102 Pump t 1
796-946-1310 Guide 21.8
1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide 20.9
1 1
(For 723-46-44100)
796-946-2210 Guide 20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide 21.6
1
(For 723-46-42800)
2
Control valve 796-946-2120 Guide Replacement of pressure
L 1
assembly (For 723-46-44100) compensation valve seal
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller t 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
Center swivel joint Disassembly, assembly of
M • 790-101-2540 • Washer 1
assembly center swivel joint assembly
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
30-8 PC400/450(LC)-7
(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
Disassembly, assembly of
1 790-502-1003 Cylinder repair stand t 1
hydraulic cylinder assembly
790-102-4300 Wrench assembly t 1 Removal, installation of pis-
2
790-102-4310 Pin t 2 ton assembly
3 790-720-1000 Expander q 1
Ring (For boom and
796-720-1680 q 1
bucket)
Clamp (For boom Installation of piston ring
4 07281-01589 q 1
and bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
• Push tool
Hydraulic cylinder • 790-201-1851 1
N (For bucket)
assembly
• Push tool
• 790-201-1861 1
5 (For boom) Press fitting of bushing
• Push tool (For arm)
• 790-201-1871 1
120
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
6 • Plate Press fitting of dust seal
• 790-201-1660 1
(For bucket)
• 790-201-1670 • Plate (For boom) 1
• 790-201-1680 • Plate (For arm) 1
796-670-1100 Remover q 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
• 796-670-1130 • Screw 1
Work equipment • 796-870-1110 • Adapter 1
P Removal of foot pin
assembly • 01643-33080 • Washer 1
• 01803-13034 • Nut 1
Puller (490 kN {50t},
790-101-4000 q 1
long)
790-101-1102 Pump (294 kN {30t}) q 1
PC400/450(LC)-7 30-9
(2)
New/remodel
Necessity
Symbol
Sketch
Q'ty
799-703-1200 Service tool kit t 1

Vacuum pump
799-703-1100 t 1
(100V)
Air conditioner Vacuum pump Filling with air conditioner
Q 799-703-1110 t 1
unit assembly (220V) refrigerant (gas)
Vacuum pump
799-703-1120 t 1
(240V)
799-703-1401 Gas leak detector t 1
Lifter
Operator’s cab 1 793-498-1210 t 2 Removal and Installation of
Y (Suction cup)
glass operator’s cab glass
2 20Y-54-13180 Adapter t 2
30-10 PC400/450(LC)-7
(5)
SKETCHES OF SPECIAL TOOLS
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A6. Push tool
A8. Wrench
PC400/450(LC)-7 30-11
(2)
B. Stopper
D1. Push tool
30-11-1 PC400/450(LC)-7
(5)
D7. Push tool
E2. Push tool
30-12 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOLS 7. Remove fuel filter (8) and bracket (9).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 795-799-1170 Puller t 1
A
2 790-331-1110 Wrench q 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery. 8. Remove clamp (10), 2 tubes (11), and filter (12).
1. Remove 2 engine undercovers (1). 9. Remove cap (13) and disconnect wire (15).
10. Disconnect heater switch (14).
11. Remove the 2 clips on the back side and

remove bracket (16).
2. Drain the coolant.
6 Coolant: Approx. 35 l
3. Open the engine hood.

12. Disconnect fuel supply pump wiring connectors
4. Remove tube (2). [*1] PCV1 (17) and PCV2 (18) and remove 2 clips
a Remove the tube and bracket together. (19).
5. Remove clamp (4) and disconnect the bracket 13. Disconnect bracket (20) and connector PIM (21)
and pipe (5) together. [*2] and remove spacer (22). [*4]
a Fix hose (3) and pipe (5) with cords, etc.
apart from the engine.
6. Remove 2 clamps (6) and 2 tubes (7). [*3]
PC400/450(LC)-7 30-13
(2)
14. Disconnect clip (23) and bracket (24), and then 17. Remove 3 high-pressure pipe clamps (31) and 3
disconnect 6 fuel injector connectors (25). brackets (32). [*6]
a Place disconnected wiring harness assem-
bly (26) so that it will not be an obstacle. [*4] 18. Remove lubrication tube clamp (33).
a To disconnect fuel injector connector "c", in- 19. Sling air intake manifold assembly (34) tempo-
sert flat-head screwdriver [1] in stepped part rarily and remove the air intake manifold mount-
"a" and move it in direction "X", pressing ing bolts. [*7]
stopper "b". a Do not remove XX.
20. Lift off air intake manifold assembly (34).
4 Air intake manifold assembly: 45 kg
15. Remove common rail-side high-pressure pipe

clamp (28), cover (27), and gate-type bracket
(29). [*5]
16. Remove each high-pressure pipe cover (30). 21. Remove mounting bolts (35) and disconnect
[*5] lower lubrication tube (36).
22. Remove heat insulation cover (37) and cover

(38).
30-14 PC400/450(LC)-7
(2)
23. Remove clip (39) and lubrication tubes (40) and 29. Remove coolant tube (48). [*13]
(36). [*8]
a Take care of the spacer. 30. Remove each high-pressure pipe cover (49).
[*14]
24. Remove clamp (41). [*9]
25. Remove cover (44).
26. Remove clamp (42) and disconnect hose (43).

[*10]
31. Remove 6 high-pressure pipe sleeve nuts (50)

on the common rail side. [*15]
32. Loosen 6 high-pressure pipe sleeve nuts (51) on

the head side and remove 6 high-pressure pipes
(52). [*16]
27. Sling turbocharger assembly (45) temporarily
and remove the mounting bolts of exhaust mani- 33. Remove spill tube (55). [*17]
fold (46). [*11]
34. Remove return tube (53). [*18]
35. Remove 6 head covers (54). [*19]
28. Lift off turbocharger and exhaust manifold

assembly (47).
4 Turbocharger and exhaust manifold

assembly: 75 kg
a When lifting up, remove part A. Note that the
center of gravity is off to the left. [*12]
PC400/450(LC)-7 30-15
(2)
36. Remove capture nut (56) and disconnect the INSTALLATION

wiring harness from the injector. [*20] • Carry out installation of all the parts, except the
high-pressure pipe, in the reverse order to
37. Remove rocker shaft mounting bolts (57) and removal.
rocker arm and rocker shaft assembly (58). [*21]
3 Hose clamp:
[*1]
38. Remove injector mounting bolts (59) and injec-
tor assembly (60). [*22] 9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
a If the injector assembly is not removed easi-
3 Air aftercooler pipe clamp:

ly, use tool A1. [*2]
a Do not hold the solenoid valve on the top of
the injector with pliers, etc. 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Fuel tube (7):

[*3]
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]
Install wiring harness assembly (26) and other
wiring harnesses at least 10 mm apart from the
high-pressure pipe.
[*7]
The tightening torque and tightening order of the
air intake manifold assembly mounting bolts are
39. Remove cross head (61). [*23] not specified.
3 Joint bolt on engine block side of lubri-

40. Remove 2 push rods (62). [*8]
cation tube:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp (41):
[*9]
68.6 – 98 Nm {7 – 10 kgm}
3 Hose clamp:
[*10]
10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*11]
Tighten the following 3 exhaust manifold assem-
bly mounting bolts first in the given order, and
41. Remove 6 mounting bolts (63) and rocker hous-
3 Exhaust manifold assembly mounting
then tighten the other bolts.
ing (64). [*24]
bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
42. Remove 7 cylinder head mounting bolts (65)
and cylinder head assembly (66). [*25]
30-16 PC400/450(LC)-7
(2)
2 All periphery of inserting part of

[*12]
exhaust pipe: Thermosetting sealant

(FIREGUM manufactured by HOLTS
or equivalent)
3 Coolant tube (48):

[*13]
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*14]
a For the installation procedure for high-pressure
pipe cover (49), see REMOVAL AND INSTALLA-
TION OF FUEL INJECTOR ASSEMBLY.
3 Spill tube (55):

[*17]
[*5] [*6] [*15] [*16]
Installation procedure for high-pressure pipe 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
a Do not correct the high-pressure pipe by bending
before installing it.
3 Return tube:
[*18]
1) Tighten high-pressure pipe (52) perma-
3 Sleeve nuts (50) and (51):

nently. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
39.2 – 49.0 Nm {4.0 – 5.0 kgm}

3 Head cover mounting bolt:
[*19]
2) Tighten high-pressure pipe clamps (28) and
(31) and bracket (32) with your fingers. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3) Tighten high-pressure pipe clamps (28) and
3 Clamp bolt:
(31) permanently.
3 Capture nut:
[*20]
11.8 – 14.7 Nm {1.2 – 1.5 kgm} 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
4) Tighten bracket (32) permanently.
5) Install cover (30). [*21]
a Set the slit on the cylinder head side. 1) Loosen the locknut and install the rocker arm
6) Install gate-type bracket (29) and cover
3 Rocker shaft mounting bolt:
and rocker shaft assembly.
(which is used as the clamp, too) (27) tem-
porarily. 58.8 – 73.5 Nm {6 – 7.5 kgm}
3 Cover mounting bolt:

7) Tighten cover (27) permanently. 2) Remove covers (70) and (71) and adjust the
valve clearance. The pointer is under cover (70).
11.8 – 14.7 kgm {1.2 – 1.5 kgm} • Valve clearance
8) Tighten the gate-type bracket permanently. Intake: 0.33 mm
Exhaust: 0.71 mm
a For the adjustment procedure for the valve clear-
ance, see TESTING AND ADJUSTING, Adjust-
3 Rocker arm locknut:

ing valve clearance.
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
PC400/450(LC)-7 30-17
(2)
[*22] [*25]
a For the installation procedure for the injector and a Clean the underside of the head, top of the block,
holder, see REMOVAL AND INSTALLATION OF and liner with dry cloths or cloths soaked with
FUEL INJECTOR ASSEMBLY. solvent.
a If a bolt has 5 punch marks on its head, replace it.
[*23] a Tighten the bolts with your fingers into the block
2 Bolt threads and underside of bolt

a Apply engine oil (EO30-CD) to the cross head at least 2 turns.
guide and cross head top sufficiently.
a Adjust the cross head according to the following head: LM-P or engine oil (EO30-CD)
procedure. a Tighten the cylinder head mounting bolts in the
3 Cylinder head mounting bolts 1 – 6:

following order.
1) Loosen locknut (73) and return the adjust-
ment screw. 1st time: 88.3 – 108 Nm {9 – 11 kgm}
2) Press the cross head top lightly to put it to 2nd time: 157 – 167 Nm {16 – 17 kgm}
valve stem (74) and tighten the adjustment 3rd time:
screw. 1) When using tool A2
3) After the adjustment screw touches the
valve stem, tighten it further by 20°.
3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}

4) Tighten the locknut at this position.
Using tool A2, retighten the bolts in the

order of 1 – 6 by 90° +30°
0 .
3 Rocker housing mounting bolt:

[*24]
58.8 – 73.5 Nm {6 – 7.5 kgm}
30-18 PC400/450(LC)-7
(2)
2) When not using tool A2

Make marks on the bolt heads with a marker
pen and retighten the bolts in the order of 1
– 6 by 90° +30°
0 .
a After tightening bolts 1 – 6, tighten auxil-
3 Cylinder head auxiliary mounting

iary bolt 7.
bolt 7:
66.2 ± 7.4 Nm {6.8 ± 0.8 kgm}
a After tightening the bolts, make a punch
mark on each bolt head to show the
number of tightening time.
• Refilling with coolant

Add coolant through the coolant filler of the radi-
ator to the specified level. Run the engine to cir-
culate the coolant through the piping. Then,
check the coolant level again.
PC400/450(LC)-7 30-19
(2)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

SPECIAL TOOLS 4. Leave 1 mounting bolt (5) and sling flywheel (4)
temporarily. [*3]
New/Remodel
a Sling [2] becomes diagonal because of the
Necessity
muffler.
Symbol
Sketch
Q’ty
Part No. Part Name
5. Lift off flywheel assembly (4). [*3]
4 Flywheel assembly: 50 kg
k
3 795-931-1100 Seal puller t 1
When the flywheel is hung temporarily, sling
795-931-1210 Push tool t 1 [2] becomes diagonal. Accordingly, when
flywheel assembly (4) (which has been fit-
4 • 01050-31625 • Bolt t 3 ted firmly) is removed, it swings. Take care.
A
• 01050-31645 • Bolt t 3
795-931-1220 Push tool t 1
5
• 01050-31645 • Bolt t 3
REMOVAL
1. Remove they hydraulic pump assembly. For
details, see REMOVAL AND INSTALLATION OF
HYDRAULIC PUMP ASSEMBLY.
2. Using guide bolt [1], remove damper assembly

(1). [*1]
6. Rear seal
Remove rear seal (6) according to the following
procedure. [*4]
3. Disconnect engine speed sensor connector

EREV (2), loosen speed sensor locknut (3), and
separate the speed sensor from flywheel (4).[*2]
30-20 PC400/450(LC)-7
(2)
• Removal of original rear seal INSTALLATION

Set the drill-type tip to tool A3, make a hole • Carry out installation in the reverse order to
on the seal, and pull out the seal with the removal.
impact force of the slide hammer (SH).
a Remove all the chips.
2 Mounting bolt: Adhesive (LT-2)
[*1]
[*2]
Installation procedure for sensor
2 Threads of sensor: Hydraulic

1)
sealant manufactured by LOC-

TITE
2) Screw the sensor into the flywheel housing
to touch it to the ring gear.
3) Return the sensor by 1/2 – 2/3 turns. (Clear-
ance between the sensor and ring gear:
0.75 – 1 mm)
3 Sensor locknut:
• Removal of spare rear seal 4)
1) Set the hook-type tip to tool A3, hook it to
the metallic ring of seal (6), and pull out the 69 – 74 Nm {7 – 7.5 kgm}
seal with the impact force of the slide ham-
mer (SH). [*3]
a Drive in the seal a little before pulling it a Apply sufficient amount of clean lubricating
out to separate it from the housing, and oil (EO30-CD) to the threads of the bolt, seat,
you can put it out easily. and washer.
2) If sleeve (9) is installed, cut and remove it a Tighten the 6 flywheel assembly mounting
with a chisel and a hammer. bolts in the order of 1 – 6 shown in the follow-
a When cutting sleeve (9), take care ex- ing figure.
tremely not to damage crankshaft (8). a Tighten the flywheel assembly mounting
a If chips are made, remove all of them. bolts 2 times.
3 Mounting bolt:
1st tightening torque:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd tightening torque:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
PC400/450(LC)-7 30-21
(2)
[*4] 1) Put large inside diameter side "b" of internal

• Installation procedure for engine rear seal (6) plastic cylinder (7) to the end of crankshaft
a Rear seal 6151-21-4161: Check the shaft for (8).
wear and install "standard seal A" or a Take care not to mistake the direction of
"sleeved seal B" according to the check re- the plastic internal cylinder.
sult.
The part No. of the spare rear seal is 6151-
29-4160 (same as one installed to PC400-6)
and its shape is different from that of the
seal installed when shipped.
a If the shaft is still glossy (If the wear depth felt
with a finger cushion is 10 m or less) and
it does not have a flaw, install "standard seal
A". In other cases, install "sleeved seal B".
a Part (7) is the internal plastic cylinder which
is also used as a installation guide.
a Part (9) is the sleeve.
a Wipe off oil from the crankshaft and install
the seal while the crankshaft is dry (Do no 2) Evenly push in the metallic ring of seal (6)
apply lubricating oil to the lip). with both hands, getting over the large
diameter side of the internal plastic cylinder.
3) After pushing in seal (6), remove internal
plastic cylinder (7).
a When removing, take care not to dam-
age the seal lip.
• Installation procedure for standard seal A

a Before installing the seal, check the rims of
the crankshaft end, sliding surfaces of the
lip, and housing for flaw, burr, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly 4) Tighten the bolt of tool A4 evenly until the
from the shaft. end of tool A4 touches the end of crankshaft
a Never remove internal plastic cylinder (7) of (8) to press fit seal (6).
the spare seal before installing the seal. a When press fitting the seal, take care not
to damage the lip on the damper side
with the tool, etc.
a After press fitting the seal, remove the
red sealant layer on its periphery.
30-22 PC400/450(LC)-7
(2)
• Installation procedure for sleeved seal B 3) Remove tool A5 and install tool A4.
a Before installing the seal, check the rims of 4) Tighten the bolt of tool A4 evenly until the
the crankshaft end, sliding faces of the lip, end of tool A4 touches the end of crankshaft
and housing for flaw, burr, sharp fin, rust, etc. (8) to press fit sleeved seal (6).
a When installing the seal, do not apply oil, a After press fitting the seal, remove the
grease, etc. to the shaft. Wipe oil thoroughly red sealant layer on its periphery.
from the shaft.
a Handle the seal and sleeve as an assembly.
Never separate them from each other.
1) Set sleeved seal (6) to tool A5.
a Take care not to mistake the direction of
2 Internal cylinder (C) of sleeve:

the seal.
Gasket sealant (LG-7)
2) Put the sleeve of the seal to the end of the

crankshaft and tighten the bolt of tool A5
evenly until the end of tool A5 touches the
end of crankshaft (8) to press fit sleeved
seal (6).
PC400/450(LC)-7 30-23
(2)
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS 5. Remove covers (5) and (6).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Seal puller
A3 795-931-1100 t 1
assembly
795T-521-1140 Push tool t 1 Q
• 790-101-5221 • Grip t 1
A6
• 01010-81225 • Bolt t 1
• 01050-31640 • Bolt t 3 6. Loosen the air conditioner compressor assem-
bly mounting bolt and adjustment screw (7). [*2]
7. Loosen alternator assembly mounting bolt (11),

REMOVAL
adjustment bolt nuts (8) and (9), and adjustment
1. Remove the radiator and hydraulic oil cooler.
bolt guide bolt (10). [*3]
For details, see REMOVAL AND INSTALLA-
TION OF RADIATOR and REMOVAL AND
INSTALLATION OF HYDRAULIC OIL COOLER.
2. Open the right side cover.
3. Remove reservoir tank bracket (1) and discon-

nect air aftercooler hoses (2) and (3). [*1]
4. Remove the 4 mounting bolts and air aftercooler

(4).
8. Remove fan (12).
30-24 PC400/450(LC)-7
(2)
9. Remove alternator belt (13) and air conditioner INSTALLATION

compressor belt (14). • Carry out installation in the reverse order to
removal.
10. Remove 6 pulley mounting bolts (15) and (16) in
3 Air aftercooler hose clamp:

total, and then remove pulley and damper [*1]
assembly (17).
a One mounting bolt (16) is small in diameter. 10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*4]
[*2]
a Belt tension: 14 – 16 mm
(When pressed with finger to about 58.8 N
3 Mounting bolt:
{6 kg})
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
[*3]
• Tense the belt according to the following pro-
cedure.
1) Loosen mounting bolt (11), nut (9), and bolt
(10).
2) Tense the belt with nut (8).
11. Using the seal pulley assembly and tool A3, 3) Tighten mounting bolt (11), nut (9), and bolt
remove the front seal. [*5] (10).
a Remove all the chips. a Tension of belt: 13 mm
(When pressed with finger to about 58.8
3 Bolt:
N {6 kg})
107.8 – 147 Nm {11 – 15 kgm}
3 Pulley mounting bolt:

[*4]
(M14): 156.8 – 196 Nm {16 – 20 kgm}

(M16): 245 – 308.7 Nm {25 – 31 kgm}
PC400/450(LC)-7 30-25
(2)
[*5] ii) Evenly push in the metallic ring of seal

4) Installation procedure for front seal (18) (18) with both hands, getting over the
a Before installing the seal, check the rims large diameter side of the internal plas-
of the crankshaft end, sliding surfaces of tic cylinder.
the lip, and housing for flaw, burr, rust, iii) After pushing in seal (18), remove inter-
etc. nal plastic cylinder (19).
a When installing the seal, do not apply oil, a When removing, take care not to dam-
grease, etc. to the shaft. Wipe oil thor- age the seal lip.
oughly from the shaft.
a Never remove internal plastic cylinder of
the spare seal before installing the seal.
iv) Tighten the bolt of tool A5 evenly until

the end of tool A6 touches the end of
crankshaft (20) to press fit seal (18).
i)Put large inside diameter side "b" of a When press fitting the seal, take care not
internal plastic cylinder (19) to the end to damage the lip on the pulley side with
of crankshaft (20). the tool, etc.
a Take care not to mistake the direction of a After press fitting the seal, remove the
2 Lip: Lithium grease (G2-LI)

the plastic internal cylinder. red sealant layer on its periphery.
a Seal driving dimension "a": 16 +10 mm
30-26 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP

ASSEMBLY
SPECIAL TOOLS 4. Open the engine hood.
New/Remodel
5. Remove air cleaner tube (2) and bracket
Necessity
together. [*1]
Symbol
Sketch
Q’ty
Part No. Part Name
6. Fix hose (3) with cords apart from the engine.

795-471-1800 Remover t 1 N
• 795-471-1810 • Plate 1
• 795-471-1820 • Bolt 1
A7
• 795-471-1830 • Bracket 1
• 01435-01035 • Bolt 3
• 01435-01025 • Bolt 1
REMOVAL
minal of the battery.
8. Remove clamp (5).
1. Release the residual pressure from the fuel sys-
9. Disconnect fuel supply pump wiring connectors
tem. For details, see TESTING AND ADJUST-
PCV1 (6), PCV2 (7), and G (8).
ING, Releasing residual pressure from fuel
system.
10. Remove fuel hoses (9) and (10). [*2]
2. Close the fuel supply valve of the fuel tank.
11. Remove cover (11). [*3]
3. Remove two engine undercovers (1).
PC400/450(LC)-7 30-27
(2)
12. Remove 4 high-pressure pipe clamps (12). [*4] 4) Install plate (23) of tool A7 to installation
hole B and install bracket (24) of tool A7 to
13. Remove 2 clamps (13) and fuel tubes (14) and C.
(15). [*5] 5) Set bolt (25) of tool A7.
a Keep tool A7 installed until the pump is in-
14. Remove 2 covers (16). [*3] stalled so that meshing point of the fuel sup-
ply pump drive gear and camshaft will
15. Remove 2 high-pressure pipes (17). [*6] change.
16. Remove lubrication tube (18). [*7]
18. Remove bracket (26) and mounting bolts of fuel

supply pump assembly (27) and install guide
17. Setting tool to remove fuel supply pump bolt [1]. [*10]
drive gear a The proper length of the guide bolt is a half
1) Remove 2 mounting bolts (19) and cover of the length shown in the photo.
(20). [*8]
19. Remove the remaining 3 mounting bolts.
2) Remove mounting nut (22) and the washer

of fuel supply pump drive gear (21). [*9] 20. Tighten bolt (25) of tool A7 to remove fuel sup-
3) Rotate the crankshaft so that key way A of ply pump assembly (27).
the shaft will be in the 11 o'clock direction.
30-28 PC400/450(LC)-7
(2)
INSTALLATION 3) Tighten the fuel supply pump mounting

• Carry out installation in the reverse order to bolts.
removal.
4) Tighten the mounting bolts of bracket (26).
3 Air cleaner hose clamp:

[*1]
5) Tighten 4 high-pressure pipe clamps (12)
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm} temporarily with your fingers.
3 Fuel hoses (9) and (10):

[*2] 6) Tighten 4 high-pressure pipe clamps (12) to
3 High-pressure pipe clamp:

the following torque.
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*3]
a Install cover (11) with the slit on the cylinder
block side and install cover (16) with the slit di-
rected down.
[*4], [*6], [*10]

k Do not correct the high-pressure pipe by bend-
ing before installing it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified torque.
k Install the wiring harnesses at least 10 mm apart
from the high-pressure pipe.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part "a": Part of 2 mm
3 Fuel tubes (14) and (15):
[*5]
from the end) for visible lengthwise slit "b" and
spot "c" and check part "d" (End of taper seal: 24.5 – 34.3 {2.5 – 3.5 kgm}
Part of 2 mm from the end) for stepped-type wear
caused by fatigue which your nail can feel. If
3 Lubrication tube (20)
[*7]
there is any of those defects, it can cause fuel
leakage. In this case, replace the high-pressure Fuel supply pump side:
pipe. 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Cylinder block side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
3 Cover: 14.7 – 17.6 Nm {1.5 – 1.8 kgm}

[*8]
3 Fuel supply pump drive gear:

[*9]
127 – 147 Nm {13 – 15 kgm}
• Checking for fuel leakage

a Check the fuel system for leakage. For de-
1) Tighten fuel supply pump (27), bracket (26), tails, see TESTING AND ADJUSTING,
and 2 high-pressure pipes (17) temporarily Checking fuel system for leakage.
2 Fuel supply pump mounting bolt:

with your fingers.
• Bleeding air
LOCTITE (LT-7) a Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air
2) Tighten 2 high-pressure pipes (17) to the fol- from fuel circuit.
3 Common rail-side sleeve nut:

lowing torque.
39.2 – 58.8 Nm {4.0 – 6.0 kgm}

Supply pump-side sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
PC400/450(LC)-7 30-29
(2)
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY

SPECIAL TOOL 5. Remove gate-type bracket (4). [*4]
New/Remodel
6. Remove injector-side covers (6) and common
Necessity
rail-side covers (5) from the high-pressure pipe
Symbol
Sketch
Q’ty
Part No. Part Name joints according to the fuel injectors to be
removed and installed. [*5]
7. Remove high-pressure pipe clamp cover (7) and

A1 795-799-1170 Puller t 1
its clamp (77) according to the fuel injectors to
be removed and installed. [*6]
a Do not remove bracket X. If it is removed,
REMOVAL tighten it permanently after tightening the
k Disconnect the cable from the negative (–) ter- high-pressure pipe and all the high-pressure
minal of the battery. pipe clamps in the assembly procedure.
2. Remove air cleaner tube (1) and the bracket

together. [*1]
8. Loosen common rail-side sleeve nuts (8) and

fuel injector-side sleeve nut (10) and remove
high-pressure pipe (9). [*7]
9. Remove head cover (11). [*8]

3. Remove common rail cover (2). [*2]
4. Remove high-pressure pipe clamps (3) accord-

ing to the fuel injectors to be removed and
installed. [*3]
30-30 PC400/450(LC)-7
(2)
10. Remove capture nuts (12) and disconnect wiring

harness (13) from the fuel injector. [*9]
11. Remove holder mounting bolt (14), and then

remove the holder and fuel injector assembly
(16) together. [*10]
a Do not grip the solenoid valve at the top of
the injector with pliers, etc.
a Install high-pressure pipe (9) between the

common rail and fuel injector according to
1) Tighten sleeve nuts (8) and (10) of high-
3 High-pressure pipe sleeve nut:

pressure pipe (9).
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
a If the fuel injector is not removed easily, use 2) Tighten high-pressure pipe clamps (3) and
tool A1. (77) temporarily with your fingers, and then
tighten them permanently.
3) Install common rail cover (2) and gate-type
INSTALLATION bracket (4) temporarily.
• Carry out installation in the reverse order to 4) Tighten common rail cover (2) (which is also
removal. used as a high-pressure pipe clamp) perma-
nently first, then tighten gate-type bracket
3 Air cleaner tube band: 3 Common rail cover:

[*1] (4) permanently.
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm} 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*2] [*3] [*4] [*6] [*7]

k Do not correct the high-pressure pipe by bend-
ing before installing it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified torque.
k Install the wiring harnesses at least 10 mm apart
from the high-pressure pipe.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part "a": Part of 2 mm
from the end) for visible lengthwise slit "b" and
spot "c" and check part "d" (End of taper seal:
Part of 2 mm from the end) for stepped-type wear
caused by fatigue which your nail can feel. If
there is any of those defects, it can cause fuel
leakage. In this case, replace the high-pressure
pipe.
PC400/450(LC)-7 30-31
(2)
[*5]
a Install common rail-side cover (5) with the slit
on the cylinder block side.
a Set the slit on fuel injector-side cover (6) at
position "a" in the figure and match it to the
center of the clip.
• Checking for fuel leakage

Check the fuel system for leakage. For details,
see TESTING AND ADJUSTING, Checking fuel
system for leakage.
• Bleeding air
3 Head cover mounting bolt:

[*8] Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
9.8 ± 1 Nm {1.0 ± 0.1 kgm} fuel circuit.
3 Wiring harness mounting nut:

[*9]
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
[*10]
a Install fuel injector assembly (16) according to
1) Insert gasket (b) and O-ring (c) in fuel injec-
tor (a).
2) Put holder (d) in injector (a) and install them
to the rocker housing temporarily.
a Matching key (g) of the injector to key
way (h) of the rocker housing, insert the
holder securely until the sealing surface
of the injector touches the sealing sur-
face on the cylinder head side.
3) Apply engine oil to the spherical part of
spherical washer (e).
3 Holder mounting bolt:

4) Tighten holder mounting bolt (f).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
30-32 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP

a [ERA Regulation] 3. Using 19-mm deep socket [3], loosen retaining
In a country where EPA Regulation is applied, nut (4).
replace the nozzle of the common rail engine by
the assembly. In a country where EPA Regula-
tion is not applied, however, only the nozzle tip
can be replaced according to the following pro-
cedure.
(EPA: Environmental Protection Agency)
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Part No. Part Name Q’ty
4. Remove retaining nut (4) from injector assembly

A8 795T-471-1550 Wrench q 1 (3).
5. Lift up and remove nozzle assembly (5) verti-

cally.
REMOVAL
a Do not remove tip guide (6). (The tip guide
1. Grip tool A8 with vise [1].
cannot be disassembled.)
a Do not grip the injector directly with the vice.
a Take care that dirt will not stick to the parts.
2. Set injector assembly (3) to tool A8.
PC400/450(LC)-7 30-33
(2)
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
INSTALLATION 5. Install nozzle assembly (3) and tighten retaining

1. Grip tool A8 with vise [1]. nut (2) with the fingers.
a Do not hold the injector directly with the vice.
6. Set 19-mm deep socket [2] to a torque wrench

2. Set injector assembly (1) to tool A8. and tighten the retaining nut according to the fol-
lowing procedure.
3. Clean the lower body and the threads of retain- a Apply rust-preventive oil to the nozzle body.
ing nut (2) throughly with parts cleaner and blow 1) Tighten the retaining nut to 88.3 Nm {9.0
air against them. kgm}.
2) Make match marks (6) on retaining nut (2)
and lower body (5).
3) Tighten the retaining nut by 45° (Angle tight-
ening).
4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).
a Take care not to drop the tip.
30-34 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL AND INSTALLATION OF STARTING MOTOR

ASSEMBLY
REMOVAL INSTALLATION
k Disconnect the cable from the negative (–) ter- • Carry out installation in the reverse order to
minal of the battery. removal.
3 Mounting nut of starting motor terminal

1. Open the engine hood. [*1]
2. Disconnect the following 2 starting motor wires. B: 19.6 – 25.5 Nm {2 – 2.6 kgm}
[*1]
• (1) and (2): Terminal B
3. Remove 3 mounting bolts (3) and starting motor

assembly (4).
PC400/450(LC)-7 30-35
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL
4. Disconnect reservoir tank hose (6).

a Disconnect the hose from the radiator.
2. Drain the coolant.
6
5. Disconnect radiator hoses (7), (8), and (9). [*1]
Coolant: Approx. 35 l
6. Remove covers (10) and (11).
3. Erect the engine hood according to the following
procedure.
1) Open engine hood (2) and sling it temporar-
ily.
a When slinging the engine hood, take
care not to damage the rubber seal.
2) Prepare M10 bolt [1].
• When removing the radiator, L = 50 or
longer.
• When removing the oil cooler, L = 70 or
longer.
3) Remove bolt (4).
4) Remove pin (5) from the lower part of stay
(3). 7. Remove cover (12).
5) Adjust the engine hood so that center hole A
of stay (3) will be at the bolt (4). 8. Disconnect radiator hose (13). [*1]
6) Install stay (3) with bolt [1] and fix engine
hood (2) vertically.
30-36 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY RADIATOR
9. Remove 2 mounting bolts (14). INSTALLATION

• Carry out installation in the reverse order to
removal.

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
3 Radiator hose clamps

[*1]
10. Lift off radiator assembly (15). (7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm}
4 Radiator assembly: 30 kg (9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
PC400/450(LC)-7 30-37
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY
REMOVAL
2. Remove plug (2) of the hydraulic oil cooler drain

hose to drain the hydraulic oil.
a Before draining, open the hydraulic tank cap
to release the pressure in the tank. Then,
drain the oil through the cooler hose.
5. Remove hydraulic oil cooler tube mounting bolts

(5) and (6).
6. Remove right and left hydraulic oil cooler mount-

ing bolts (7).

procedure.
1) Open engine hood (100) and sling it tempo-
rarily.
a When slinging the engine hood, take
3) Remove bolt (102).
4) Remove pin (103) from the lower part of
stay (101).
5) Adjust the engine hood so that center hole A
of stay (101) will be at the bolt (102).
6) Install stay (101) with bolt [1] and fix engine
hood (100) vertically.
30-38 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
7. Remove 3 hydraulic oil cooler-side mounting INSTALLATION

bolts (8). • Carry out installation in the reverse order to
a When removing 1 of the 3 bolts which is hid- removal.
den behind cover B, pull cover B lightly.
a Bolt [1] is used to fix the engine hood verti- • Refilling with oil (Hydraulic tank)
cally. 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.
8. Remove the net on the outside of the hydraulic

oil cooler.
9. Lift off hydraulic oil cooler assembly (9).
4 Hydraulic oil cooler: 50 kg
PC400/450(LC)-7 30-39
(2)
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC

PUMP ASSEMBLY
SPECIAL TOOLS 3. Drain the coolant.
New/Remodel
Coolant: Approx. 35 l
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name 4. Close the fuel stop valve of the fuel tank.

procedure.
B 796-601-1110 Stopper t 1 N
1) Open engine hood (100) and sling it tempo-
796-460-1210 Oil stopper t 1 rarily.
C a When slinging the engine hood, take
796-770-1320 Adapter t 1
3) Remove bolt (102).
REMOVAL 4) Remove pin (103) from the lower part of
k Disconnect the cable from the negative (–) ter- stay (101).
minal of the battery. 5) Adjust the engine hood so that center hole A
k Lower the work equipment to the ground and of stay (101) will be at the bolt (102).
stop the engine. Then, loosen the hydraulic oil 6) Install stay (101) with bolt [1] and fix engine
filler cap slowly to release the internal pressure hood (100) vertically.
of the hydraulic tank.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.
1. Remove the 4 engine undercovers.
2. Remove the hydraulic tank strainer. Using tool

C, stop the oil.
a When not using tool C, remove the drain plug
to drain the oil from the hydraulic tank and
piping.
6 Hydraulic tank: Approx. 335 l

6. Remove tube (1). [*1]
a Remove the tube and bracket together.
7. Disconnect clamp (2) and pipe (3). [*2]

a Remove the clamp, pipe, and bracket (4) to-
gether.
30-40 PC400/450(LC)-7
(2)
8. Disconnect fuel inlet hose (5) and fuel return

hoses (6) and (7). [*3]
15. Disconnect aftercooler hose (21) and heater

hose (22). [*6]
9. Disconnect clamp (8) and radiator hoses (9),
(10), and (11). [*4]
11. Remove fan guard (14).

a Bolt [1] is used to fix the engine hood verti-
cally.
17. Disconnect radiator hose (24). [*4]
12. Loosen adjustment bolt (15) and remove belt

(16). [*5]
13. Remove air conditioner compressor assembly

(17).
a Move the air conditioner compressor assem-
bly toward the control valve top cover.
14. Disconnect fan (18).

a Insert your hand through clearance A be-
tween the fan and the radiator and remove
the 6 fan mounting bolts in order, turning the
fan with your foot.
PC400/450(LC)-7 30-41
(2)
18. Disconnect heater hose (25).
19. Disconnect the following 2 wiring connectors. 24. Disconnect the following 2 pump wiring connec-
• (26): ERO2 (Various sensors) tors.
• (27): ERO3 (Each injector and fuel supply • (34): V22 (PC-EPC solenoid valve)
pump) Band color: Red
• (35): V21 (LS-EPC solenoid valve)
20. Remove mounting bolts (28) and bracket (29). Band color: White
25. Disconnect the following 10 hoses and 1 tube.

• (36): EPC basic pressure port hose
(Band color: Yellow)
• (37): Rear pressure port hose
• (38): Rear pump discharge port hose
• (39): Front pump discharge port hose
• (40): Drain port hose
• (41): Front load pressure input port hose
• (42): Rear load pressure input port hose
(Band color: Red)
• (43): Front pressure input port hose
21. Open the main pump side cover. • (44): Pump suction port tube
22. Lift off covers (30) and (31) together.
23. Remove cover (32) and stay (33).
30-42 PC400/450(LC)-7
(2)
28. Lift off engine and hydraulic pump assembly

(48).
a Check that all the wires and pipes have been
disconnected.
4 Engine and hydraulic pump assembly:

1,700 kg
26. Disconnect engine ground cable (46) from the

rear of the hydraulic pump.
27. Using tool B, remove 4 front and rear engine

mounting bolts (47). [*7]
PC400/450(LC)-7 30-43
(2)
INSTALLATION
removal.
3 Hose clamp:
[*1]
9.8 ± 0.5 Nm {0.1 ± 0.05 kgm}
3 Clamp:
[*2]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Fuel hoses (5), (6), and (7):

[*3]
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Radiator hoses:
[*4]
(9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}

(10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
(11), (24):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
a See TESTING AND ADJUSTING, Testing
and adjusting air conditioner compressor
belt tension or REMOVAL AND INSTALLA-
TION OF ENGINE FRONT SEAL.
3 Air aftercooler hose clamp:

[*6]
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
3 Engine mounting bolt:

[*7]
824 – 1,030 Nm {84 – 105 kgm}

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
• Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
5 Hydraulic oil: Approx. 335 l
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air
from each part.
30-44 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

1. Remove the revolving frame assembly. For • Carry out installation in the reverse order to
d e t a i l s , s e e R E M O VA L O F R E V O LV I N G removal.
FRAME ASSEMBLY.
2 Mating face of swing circle:

[*1]
2. Sling swing circle assembly (1) by 3 points tem-
2 Threads of swing circle mounting bolt:

porarily, remove 40 mounting bolts, and lift off Gasket sealant (LG-6)
the swing circle assembly. [*1]
4 3 Swing circle mounting bolt:

Adhesive (LT-2)
Swing circle assembly: 600 kg
824 – 1,030 Nm {84 – 105 kgm}
Target: 927 Nm {94.5 kgm}
a When installing the swing circle to the track
frame, bring soft zone mark S of the inner
race and soft zone mark P of the outer race
to the right side of the chassis as shown be-
2 Quantity of grease in grease bath:

low.
Grease (G2-LI), 33 l
(Use GLT2-LI for 50°C specification)
PC400/450(LC)-7 30-45
(2)
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING

MACHINERY ASSEMBLY
3. Lift and remove swing motor and swing machin-
REMOVAL ery assembly (6).
k Release the residual pressure in the hydraulic a When lifting the swing motor and swing ma-
circuit. Refer to the Releasing of Residual Pres- chinery assembly for removal, do so slowly
sure in Hydraulic Circuit section in the TESTING so that the hoses and other parts will not be
AND ADJUSTING chapter of this manual. damaged.
k Lower the work equipment to the ground for oil a Take good care, when lifting the assem-
filler cap on the fuel tank to release the residual bly, until the spigot joint portion is pulled
pressure inside the tank and move the safty lock out.
4
lever to the LOCK position.
Swing motor and swing machinery
1. Disconnect five swing motor hoses (1) through assembly: 550 kg
(5).
• (1): Between swing motor and control valve
(MA port)
• (2): Between swing motor and control valve
(MB port)
• (3): Suction hose (S port)
• (4): Drain hose (T port)
• (5): Swing brake releasing pilot hose (B
port)
INSTALLATION
• Install in reverse order of removal.
3 Mounting bolt:
[*1]
824 – 1,030 Nm {84 – 105 kgm}
• Refilling hydraulic oil

2. Detach the swing motor and swing machinery Refill hydraulic oil through the oil filler port to the
assembly (6), using forcing screw [1] after specfied level. Let the oil cirdulate in the
removing the mounting bolts. [*1] hydraulic system by starting the engine. Then
check the oil level again.
• Air bleeding
Refer to the Air Bleeding of Various Parts sec-
tion in the TESTING AND ADJUSTING chapter
of this manual.
30-46 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING

MACHINERY ASSEMBLY
SPECIAL TOOLS 3. No. 1 sun gear
Remove No. 1 sun gear (2).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 796T-627-1630 Push tool q 1

2 790-201-2350 Push tool t 1
3 790-201-2510 Push tool t 1
• 790-101-5531 • Plate 1
D 4
• 790-101-5421 • Grip 1 4. No. 1 carrier assembly
1) Remove No. 1 carrier assembly (3).
• 01010-51240 • Bolt 1 N
5 790-201-2870 Push tool t
6 790-201-2770 Push tool t
7 796T-626-1110 Push tool t Q
DISASSEMBLY
1. Draining oil
Loosen the drain plug and drain the oil from the
swing machinery case.
6 Swing machinery case: Approx. 21 l

2) Disassemble the No. 1 carrier assembly
2. Swing motor assembly
Remove snap ring (4), and then remove
1) Set the swing motor and swing machinery
shaft (5), gear (6), bearing (7), thrust washer
assembly on block [1].
(8), and plate (9).
2) Remove 10 mounting bolts and lift off swing
motor assembly (1).
4 Swing motor assembly: 115 kg
PC400/450(LC)-7 30-47
(2)
5. Ring gear 8. No. 2 carrier assembly

Remove the mounting bolts and ring gear (10). 1) Lift of No. 2 carrier assembly (13).
6. No. 2 sun gear 2) Disassemble the No. 2 carrier assembly

Remove No. 2 sun gear (11). according to the following procedure.
i) Push in pin (14) and drive out shaft (15)
from carrier (16).
a After removing the shaft, remove pin
(14).
ii) Remove thrust washer (17), gear (18),
bearing (19), and thrust washer (20).
iii) Remove plate (21).
7. Bolt
Remove holder mounting bolt (12).
9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of cover
assembly (22).
30-48 PC400/450(LC)-7
(2)
2) Turn over case and pinion assembly (24) 11. Bearing

and set it on the press stand. Using push Using multiple push tools [3], remove bearing
tool [2], D1 and the press, pull out pinion (30) from case (31).
shaft assembly (25). a Push tool to be set contact with bearing: D2
a Set a wood block under the press so that
the pinion shaft will not be damaged
when it comes off.
a A rough standard pressing force is 20
odd tons.
ASSEMBLY
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
10. Disassemble the pinion shaft assembly (25)
according to the following procedure. 1. Bearing
1) Using the push tool, remove cover assembly Using push tool D3 and [4], press fit bearing (26)
(22) and bearing (26) from shaft (27). to case (31).
a A rough standard pressing force is 30 a A rough standard pressing force is several
tons. tons.
2) Remove oil seal (28) from cover (29).
PC400/450(LC)-7 30-49
(2)
2. Cover assembly 3. Case assembly

1) Using push tool D4, press fit oil seal (28) to 1) Turn over case assembly (32) and set it to
cover (29). shaft (27). Using push tools D5 and D6 [5],
2 Periphery of oil seal:

press fit the bearing inner race.
a When setting the case assembly to the
Gasket sealant (LG-6) shaft, take care extremely not to damage
the oil seal.
a Take care that the gasket sealant (LG-6) a A rough standard pressing force is 30
will not stick to the oil seal lip and shaft tons.
assembly (22).
2) Bearing
2) Install cover assembly (22) to case (31) and Using too D7, press fit bearing (30).
tighten mounting bolts (23). a Press both inner race and outer race of
a Match the oil path of cover (22) to the the bearing simultaneously. Do not
drilled hole of case (31). press only the inner race.
2 Cover fitting face:

a A rough standard pressing force is 20
odd tons.
3 Mounting bolt:
Gasket sealant (LG-6) a After press fitting the bearing, check that
the case turns smoothly.
2 Oil seal lip: Grease (G2-LI)

98 – 123 Nm {10 – 12.5 kgm}
30-50 PC400/450(LC)-7
(2)
4. No. 2 carrier assembly a When inserting the pin, do not set the 3
1) Assemble the No. 2 carrier assembly claws (parts "a") on the periphery to the
according to the following procedure. thin part of the carrier (part "b").
a There is a caulking mark made when the The thin part may be on the opposite
pin was inserted at the end of carrier side, however. Check each carrier and
side hole "a" and the inside wall of the avoid setting a claw to the thin part.
hole is swelled at that mark. Flatten the
swelled part in advance.
i) Install plate (21) to carrier (16).
ii) 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).
a After inserting the pin, caulk the pin part

of the carrier.
2) Install No. 2 carrier assembly (13).
5. Bolt and O-ring
2 Threads of mounting bolt:

1) Tighten bolt (12).
3 Mounting bolt:
iii) Aligning the pin holes of shaft (15) and Adhesive (LT-2)
carrier, lightly hit the shaft with a plastic
hammer, etc. to install. 343 – 427 Nm {34 – 43.5 kgm}
a When installing the shaft, revolve the
planetary gear and take care not to dam-
age the thrust washers.
iv) Insert pin (14).
2) Fit the O-ring to case (31).
6. No. 2 sun gear

Install No. 2 sun gear (11).
PC400/450(LC)-7 30-51
(2)
7. Ring gear 8. No. 1 carrier assembly

Using the eyebolt (M12 x 1.75), install ring gear 1) Assemble the No. 1 carrier assembly
(10). according to the following procedure.
i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
ii) After installing snap ring (4), press back
the shaft from the opposite side until the
snap ring is fitted to face P of the carrier.
At this time, take care not to press back
too much.
a When installing ring gear (10), set its match

mark (part "d") and the projection of the case
flange (part "c") as shown in the following fig-
ure.
iii) After installing plate (9), install thrust

washer (8), bearing (7), gear (6), and
snap ring (4).
2) Install No. 1 carrier assembly (3).
a Degrease the mating faces of ring gear (10)

and case (29).
a Never stick gasket sealant to the mating fac-
3 Mounting bolt:
es of ring gear (10) and case (29).
245 – 309 Nm {25 – 31.5 kgm}

a Add engine oil (EO30-CD) at this time.
30-52 PC400/450(LC)-7
(2)
9. No. 1 sun gear assembly

Install No. 1 sun gear (2).
• Refilling with oil

a Take care not to install the No. 1 sun gear Tighten the drain plug and add engine oil
upside down. (EO30-CD, or SHC 5W-30K for extremely cold
a Install the No. 1 sun gear with the tooth (part district) through the oil filler to the specified
"e") down. level.
5 Swing machinery case: Approx. 21 l
10. Swing motor assembly

Install swing motor assembly (1) to ring gear
(10).
a When installing the swing motor assembly,
set the relief valve (part f) and the projection
of the case (part c) as shown in the following
figure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear (10).
2 Mating faces of swing motor

assembly (1) and ring gear (10):
3 Mounting bolt:
4 Swing motor assembly: 115 kg

98 – 123 Nm {10 – 12.5 kgm}
PC400/450(LC)-7 30-53
(2)
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL AND INSTALLATION OF SPROCKET
1. Remove track shoe assembly. For details, see • Install in reverse order of removal.
REMOVAL OF TRACK SHOE ASSEMBLY.
2 Thread of sprocket mounting bolt:

[*1]
2. Swing work equipment 90°, push up chassis
3 Sprocket mounting bolt:

with work equipment and place block [1] Gasket sealant (LG-6)
between track frame and track shoe.
640 – 785 Nm {65 – 80 kgm}
3. Remove mounting bolts and lift off sprocket (1).
4 Sprocket: 70 kg
[*1]
30-54 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINAL

DRIVE ASSEMBLY
REMOVAL 4. Remove the 24 mounting bolts and lift off the
1. Remove the sprocket. For details, see Removal final drive assembly (6). [*1]
of sprocket. a Take care extremely not to damage the nip-
k Lower the work equipment to the ground ple sealing faces of the hose joints.
and stop the engine. Then, loosen the hy- a When slinging the final drive assembly, do
draulic oil filler cap slowly to release the in- not use the tap hole for the cover.
4
ternal pressure of the hydraulic tank.
Final drive assembly: 700 kg
3. Disconnect drain hose (2), travel speed selector INSTALLATION

hose (3), and motor hoses (4) and (5). • Carry out installation in the reverse order to
a Remove the nipples, too. removal.
3 Mounting bolt:
[*1]
490 – 608 Nm {50 – 62 kgm}

• Bleeding air
from each part.
PC400/450(LC)-7 30-55
(2)
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SPECIAL TOOLS 2) Using eyebolt [2], remove cover (1).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Wrench
796-627-1210 t 1
assembly
• 796-627-1220 • Wrench 1
1
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q 3. Spacer
Remove spacer (2).
790-101-2510 Block q 1
791-122-1130 Plate q 1
E
790-101-2550 Leg q 2
2 790-101-2740 Adapter q 2
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (30 tons) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1
4. No. 1 carrier assembly
1) Remove No. 1 carrier assembly (3).
DISASSEMBLY
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case.
6 Final drive case: Approx. 11 l
2. Cover
1) Place the final drive on block [1] and remove
the mounting bolts and cover (1).
30-56 PC400/450(LC)-7
(2)
2) Disassemble the No. 1 carrier assembly 7. No. 2 carrier assembly

according to the following procedure. 1) Sling No. 2 carrier assembly (15) with wires,
i) Push in pin (5) to drive out shaft (6) from etc. and remove it.
carrier (7).
(5).
ii) Remove thrust washer (8), gear (9),
bearing (10), and thrust washer (11).
2) Disassemble No. 2 carrier assembly accord-

ing to the following procedure.
i) Push in pin (16) to drive out shaft (17)
from carrier (18).
5. No. 1 sun gear shaft (16).
Remove spacer (4), No. 1 sun gear (12), and ii) Remove thrust washer (19), gear (20),
No. 2 sun gear (13). bearing (21), and thrust washer (22).
6. Thrust washer 8. Nut

Remove thrust washer (14). 1) Remove lock plate (23).
PC400/450(LC)-7 30-57
(2)
2) Using tool E1, remove nut (24). ii) Remove floating seal (27) from hub
(32).
9. Hub assembly
1) Using eyebolts [3], remove hub assembly iii) Remove bearings (28) and (29) from
(25) from the travel motor. hub (32).
2) Disassemble hub assembly (25) according 3) Remove floating seal (30) from travel motor
to the following procedure. (31).
i) Remove bearing (26) from hub (32).
30-58 PC400/450(LC)-7
(2)
4) Using puller [4], remove bearing (34) and

collar (33) together.
a You can remove bearing (34) and collar
(33) without using puller [4] in some cas-
es.
3) Install collar (33) and bearing (34) to travel

motor (31).
ASSEMBLY
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Hub assembly
1) Using the push tool, press fit bearings (28)
and (29) to hub (32).
4) Using tool E3, install floating seal (30)

(which is hidden and not seen behind tool
E3) to travel motor (31).
a Thoroughly degrease and dry the O-ring
and O-ring fitting surface of the floating
seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding surfaces.
2) Using tool E3, install floating seal (27) to

hub (32).
a Thoroughly degrease and dry the O-ring
and O-ring fitting surface of the floating
seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding surfaces.
PC400/450(LC)-7 30-59
(2)
5) Using eyebolts [3], set hub assembly (25) to 7) Measure thickness "b" of nut (24).
the travel motor. Using the push tool, lightly 8) Obtain a – b = c.
hit the bearing to press fit it. 9) Using tool D1, tighten nut (24) until dimen-
sion "c" is as follows.
a Dimension "c": c +0.07–0.03 mm
2. Nut
Install the nut according to the following proce-
dure. 10) Using push-pull gauge [5], measure the tan-
1) Rotate the hub 2 – 3 turns. gential force of the hub in its revolving direc-
2) Using tool E2, press the bearing inner race. tion on the motor case.
a Pressing force: 29.4 – 38.3 kN {3.0 – 3.9 a Tangential force: Max. 765 N {78 kg}
tons} a The tangential force means the maxi-
3) While the bearing is pressed, rotate the hub mum force at the beginning of rotation.
at least 5 turns in 1 direction.
4) Release the pressing force.
5) Press the bearing again.
a Pressing force: 14.7 – 18.6 kN {1.5 – 1.9
tons}
11) Install lock plate (23), fitting it to the motor

spline.
3 Mounting bolt:
Adhesive (LT-2)
6) Under the condition in 5) above, measure
dimension "a". 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30-60 PC400/450(LC)-7
(2)

1) Assemble the No. 2 carrier assembly
a There is a caulking mark made when the
pin was inserted at the end of carrier
side hole "h" and the inside wall of the
hole is swelled at that mark. Flatten the
swelled part in advance.
i) Install bearing (21) to gear (20) and fit
top and bottom thrust washers (19) and
(22), and then set the gear assembly to
carrier (18).
4. Thrust washer
Install thrust washer (14).
ii) Aligning the pin holes of shaft (17) and

carrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care not 5. No. 2 sun gear
to damage the thrust washers. Install spacer (4) and No. 2 sun gear (13).
iii) Insert pin (16).
a After inserting the pin, caulk the pin
part of the carrier.
a After assembling the carrier assembly,
check that the gear (20) turns smoothly.

1) Assemble the No. 1 carrier assembly
a There is a caulking mark made when the
pin was inserted at the end of carrier
2) Install No. 2 carrier assembly (15). side hole "h" and the inside wall of the
a Install No. 2 carrier assembly (15) so hole is swelled at that mark. Flatten the
that the 4 gear shaft ends will be in the 4 swelled part in advance.
hollows at the motor case end.
PC400/450(LC)-7 30-61
(2)
i) Install bearing (10) to gear (9) and fit top 7. No. 1 sun gear shaft
and bottom thrust washers (8) and (11), Install No. 1 sun gear shaft (12).
and then set the gear assembly to car-
rier (7). 8. Spacer
Install spacer (2).
ii) Aligning the pin holes of shaft (6) and

carrier, lightly hit the shaft with a plastic 9. Cover
hammer, etc. to install. Using eyebolts [2], install cover (1) and tighten
a When installing the shaft, revolve the mounting bolts.
2 Cover mounting face:

the planetary gear and take care not
to damage the thrust washers.
3 Mounting bolt:
iii) Insert pin (5). Gasket sealant (LG-6)
a After inserting the pin, caulk the pin
part of the carrier. 98 – 123 Nm {10 – 12.5 kgm}
a After assembling the carrier assembly,
check that the gear (9) turns smoothly.

a Tighten the drain plug and add engine oil
2) Install No. 1 carrier assembly (4). (EO30-CD, or SHC 5W-30K for extremely
cold district) through the oil filler.
5 Final drive case: Approx. 11 l
a After installing the final drive assembly to the

chassis, check the oil level again at the spec-
ified position.
30-62 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER

ASSEMBLY
a Only precautions for assembling the carrier roller • Floating seal
assembly are explained below. a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
SPECIAL TOOLS es of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the
New/Remodel
floating seal contact surfaces.
Necessity
a Be sure to use the installer F to insert the
Symbol
Sketch
Q’ty
Part No. Part Name floating seal assembly in the housing.
a After installing the floating seal, check that its
slant is less than 1 mm and its projection "a"
is 5 – 7 mm.
1 791-430-3230 Installer t 1
F
2 791-601-1000 Oil pump t 1
4 Carrier roller assembly: 35 kg
ASSEMBLY
• Press fitting of support (2)
1) The threads of shaft (1) must be in the
range of the following figure.
2) Press fitting dimension of shaft: (Shown in
the following figure)
3) Using push tool [1], press fit support (2) to
shaft (1). At this time, apply press fitting • Carrier roller
force of at least 79 kN {8.1 tons}. a Using tool F, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the
gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
PC400/450(LC)-7 30-63
(2)
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
a Using tool F, fill the carrier roller assembly

with oil and tighten the plug.
5 Carrier roller: 170 – 180 cc (EO30-CD)
30-64 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY

a Only precautions for assembling the track roller • Track roller
assembly are explained below. a Using tool G, apply the standard pressure to
the oil filler to check the seal for air leakage.
SPECIAL TOOLS a Keep the following standard pressure for 10
seconds and check that the pointer of the
New/Remodel
gauge does not lower.
Necessity
Symbol
Standard pressure: 0.1 MPa {1 kg/cm2}
Sketch
Q’ty
Part No. Part Name
1 791-630-1780 Installer t 1
G
2 791-601-1000 Oil pump t 1
4 Track roller assembly: 80 kg
ASSEMBLY
• Floating seal
a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac- a Using tool G, fill the track roller assembly
es of the O-ring and floating seal (hatched with oil and tighten the plug.
5
3 Plug: 10 – 20 Nm {1 – 2 kgm}
floating seal contact surfaces. Track roller: 280 – 310 cc (EO30-CD)
a Be sure to use the installer G to insert the
floating seal assembly in the housing.
is 5 – 7 mm.
PC400/450(LC)-7 30-65
(2)
DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOLS 4. Remove floating seal (7) on the opposite side
from idler (5) and shaft and support assembly
New/Remodel
(6).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-575-1520 Installer t 1
H
791-601-1000 Oil pump t 1
4 Idler assembly: 250 kg
DISASSEMBLY
5. Remove nut (8), pull out bolt (9), and then

remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
1. Remove nut (1) and pull out bolt (2) to remove

support (3).
2. Remove floating seal (4) from support (3) and

idler (5).
3. Pull out idler (5) from shaft and support assem-

bly (6).
a Idler is filled with oil of 345 ± 10 cc. Drain it or
spread cloths to soak it at this time.
30-66 PC400/450(LC)-7
(2)
ASSEMBLY a When installing the floating seal, thoroughly

1. Press fit bushings (12) (on both sides) to idler clean, degrease, and dry the contact surfac-
(5). es of the O-ring and floating seal (hatched
2. Fit the O-ring and install support (10) to shaft floating seal contact surfaces.
(11) with bolt (9) and tighten nut (8). a Be sure to use the installer H to insert the
floating seal assembly in the housing.
is 9 – 11 mm.
a Install the shaft with the UP mark up.
4. Install shaft and support assembly (6) to idler

(5).
3. Using tool H, install floating seal (7) to idler (5)

and shaft and support assembly (6).
5. Similarly, using too H, install floating seal (4) to

idler (5) and support (3).
PC400/450(LC)-7 30-67
(2)
a Coat the sliding surface of the floating seal

with oil and take care that dirt will not stick to
it.
a Degrease the floating seal and the O-ring
contact surfaces.
6. Fit the O-ring, set support (3), install bolt (2), and
tighten nut (1).
7. Add oil and tighten the plug.
5 Quantity of oil:
3 Plug: 130 – 180 Nm {13 – 18 kgm}

Approx. 345 ± 10 cc (EO-30CD)
30-68 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY

SPECIAL TOOLS 1. Remove piston assembly (2) from recoil spring
assembly (1).
New/Remodel
Necessity
2. Disassembly of recoil spring assembly
Symbol
Sketch
Q’ty
Part No. Part Name 1) Set tool J1 to recoil spring assembly (1).
k 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 3
(686 kN {70 t})
790-101-1102 Pump t 3
J
790-201-1500 Push tool kit 1
• 790-201-1660 • Plate
2
• 790-101-5021 • Grip
• 01010-50816 • Bolt
4 Recoil spring (Excluding idler): 900 kg

2) Apply oil pressure gradually to compress the
DISSASSEMBLY spring and remove lock plate (3) and nut (4).
a Compress the spring to a degree that
you can loosen the nut.
a Release the oil pressure gradually to re-
duce the spring tension to 0 (zero).
a Free length of spring: 845.3 mm
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
3. Disassembly of piston assembly

1) Remove lock plate (11) from piston (10),
and then remove valve (12).
2) Remove snap ring (13), U-packing (14), and
ring (15).
PC400/450(LC)-7 30-69
(2)
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY 2) Install cylinder (7), collar (8), and yoke (6) to
2 Sliding parts of cylinder:

spring (5), and then set them to tool J1.
Grease (G2-LI)
3) Apply oil pressure gradually to compress the

spring and tighten nut (4) so that installed
length of the spring will be "a", and then
secure it with lock plate (3).
a Installed length of spring "a":
Approx. 690 mm
1. Assembly of piston assembly

1) Install ring (15) and U-packing (14) to piston
(10) and secure them with snap ring (13).
2) Tighten valve (12) temporarily and secure it
with lock plate (11).
2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylinder
4) Remove recoil spring assembly (1) from tool
(7).
J1.
3. Install piston assembly (2) to recoil spring
2 Sliding parts of piston: Grease (G2-LI)

assembly (1).
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.
30-70 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS 4. Using tool K, remove master pin (1). [*3]
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Remover and
791-650-3000 t 1
installer
K Cylinder (980
790-101-1300 t 1
kN {100 t})
790-101-1102 Pump t 1
5. Move the master pin forward and set block [1]

EXPANSION OF TRACK SHOE under the track shoe in front of the idler.
1. Start the engine and set the master pin to above
the idler. 6. Pull out pusher K.
2. Remove track shoes (2) on the right and left

sides of master pin (1). [*1]
3. Lower the work equipment to the ground and

loosen lubricator (3) to slacken the track shoe.
[*2]
k Since the internal pressure of the adjust-
ment cylinder is very high, do not loosen the
lubricator more than 1 turn. If the grease
does not come out sufficiently, move the
machine forward and in reverse.
7. Move the machine in reverse slowly to expand

the track shoe. [*4]
PC400/450(LC)-7 30-71
(2)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK SHOE 2 Apply grease to the contact faces of

• Carry out installation in the reverse order to dust seal (5) and bushing (4) (all over
expansion. the end face of the dust seal or bush-
ing) (parts marked Q). Do not apply
2 Mounting bolt: Anti-seizure com-

[*1] grease to the pars marked X, however.
R: Detail of regular pin position
pound (MARUZEN MOLYMAX No. 2 M: Detail of master pin position
3 Mounting bolt: Tighten the 4 bolts first

or equivalent) (Pins are not inserted, however)
to 392 ± 39 Nm {40 ± 4 kgm}. Check

that the mating faces are fitted, then
retighten each bolt by 120° ± 10°.
[*2]
a Adjust the tension of the track shoe. For de-
tail, see TESTING AND ADJUSTING, Test-
ing and adjusting track shoe tension.
3 Tightening torque for lubricator:

58.8 – 88.3 Nm {6 – 9 kgm}
[*3] [*4]
a Using the tool, press fit the master pin so that Set the track shoe and sprocket (4) as shown in
its projection "a" will be as follows. the following figure (on both right and left sides).
• Dimension "a": 4.4 ± 2 mm
2 Supply grease to the space between

the bushing and pin so that filling rate
will be 100%.
Grease: NIGUTAITE LYK-2 manufac-
tured by NIPPON GREASE CO., LTD.
or equivalent
30-72 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT

ASSEMBLY
SPECIAL TOOLS 4. Remove rear covers (1), (2), (3), and (4).
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
799-703-1200 Service tool kit t 1

Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
Q 799-703-1110 t 1
(220V)
Vacuum pump
799-703-1120 t 1
(240V) 5. Remove duct (5), cover (6), and plate (7).
Gas leak detec-
799-703-1401 t 1 6. Remove plate (8) and duct (9).
tor
a Remove the duct lock clip.
7. Remove ducts (10) and (11).

REMOVAL
1. Swing the upper structure by 90°.
3. Connect tool Q to cap [1] and collect the air con-

ditioner refrigerant.
8. Disconnect connectors D01 (12), D02 (13), C09

(14), R22 (15), R20 (16), and K19 (17).
9. Remove and sling controller (18).
10. Remove plate (19).
11. Disconnect air conditioner unit connectors M27

(20) and M33 (21).
PC400/450(LC)-7 30-73
(5)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12. Remove the air conditioner unit undercover. INSTALLATION

a Part A • Carry out installation in the reverse order to
removal.
a When installing the air conditioner circuit
hoses, take care that dirt, water, etc. will not
enter them.
a When connecting each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check that each O-ring is free from flaw and
deterioration.
[*1]
a Apply compressor oil (ND-OIL8) to the
threads of the refrigerant pipe joints and
tighten each nut with double spanner.
3 Hose clamp (M6 bolt):

13. Remove mounting bolt (24) and connector (25).
[*1]
8 – 12 Nm {0.8 – 1.2 kgm}
3 Hose screw of M16 x 1.5:

14. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1]
a Put tags to the disconnected hoses and 12 – 15 Nm {1.2 – 1.5 kgm}

tubes to prevent a mistake in re-connecting
them.
20 – 25 Nm {2.0 – 2.5 kgm}

30 – 35 Nm {3.0 – 3.5 kgm}
• Charging air conditioner with refrigerant gas

Using tool Q, charge the air conditioner circuit
with refrigerant (HFC R134a) from the compres-
sor.
a Quantity of refrigerant: 950 ± 50 g
15. Remove the 7 mounting bolts and air condi-

tioner unit assembly (27).
30-74 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL AND INSTALLATION OF OPERATOR’S CAB

REMOVAL 6. Disconnect connectors M71 (15), H10 (16), H11
k Disconnect the cable from the negative (–) ter- (17), and H12 (18).
7. Disconnect upper and lower duct joints (19) and
1. Remove rear covers (1), (2), (3), and (4). (20).
8. Remove controller sub-plate (21) and incline it

against the air conditioner.
2. Remove duct (5), cover (6), and plate (7).
3. Remove plate (8), duct (9) and the element.

a Remove the duct lock clip. 9. Remove cover (22) and floor mat (23).
4. Remove clip (10) and disconnect cab wiring 10. Move right console (24) into the cab.
connectors M45 (11), H08 (12), and H09 (13).
11. Remove monitor panel undercover (25).
5. Remove air conditioner connector plate (14).
PC400/450(LC)-7 30-75
(2)
12. Disconnect cab wiring connector W04 (26)

(Wiper motor).
13. Remove ducts (27) and (28).

a Both (27) and (28) are 2 in number.
a Cut the tie-wrap on the monitor wiring har-
ness.
14. Remove cover (29) and monitor assembly (30).
20. Using lever block [1], lift off operator's cab

assembly (39).
4 Operator's cab assembly: 300 kg
15. Disconnect radio antenna (31).
16. Remove clip (32) and take wiring harness (33)

out of grommet (34).
21. When starting the engine while the operator's

cab is removed (for transportation, etc.), use the
following brackets.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
17. Take grommet (35) out of the right front of the

cab.
18. Disconnect the windshield washer hose from

(36).
19. Remove 4 mounting bolts (37) and 5 mounting

bolts (38).
a Check the types of the bolts.
a In the initial period, 7 mounting bolts (38) are
used.
30-76 PC400/450(LC)-7
(2)
2) Bracket (42) for monitor panel assembly INSTALLATION

(30) • Carry out installation in the reverse order to
Part No.: 208-53-13910 removal.
PC400/450(LC)-7 30-77
(2)
DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY

1. Remove cover (1) and disconnect wiring con-

nector P15 of air conditioner sunlight sensor (2).
a Raise and remove the cover.
2. Remove the 3 mounting screws and monitor

assembly (3).
a Disconnect monitor panel wiring connectors
P01, P02, and P70 before removing the
monitor assembly.
30-78 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
REMOVAL AND INSTALLATION OF PUMP CONTROLLER

1. Remove covers (1), (2), and (3).
2. Disconnect pump controller wiring connectors

C01 (4), C02 (5), and C03 (6).
3. Remove the 4 mounting bolts and pump control-

ler assembly (7).
PC400/450(LC)-7 30-79
(2)
DISASSEMBLY AND ASSEMBLY ENGINE CONTROLLER
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER
1. Open the right side cover (cooler).
2. Remove bracket (1).
3. Remove the 4 mounting bolts and engine con-

troller assembly (2).
4. Disconnect engine controller wiring connectors

CB1 (3), CB2 (4), and CB3 (5).
30-80 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL AND INSTALLATION OF REVOLVING FRAME

ASSEMBLY
REMOVAL
k Extend the arm and bucket fully, lower the work
equipment to the ground, and set the safety lock
1. Remove the work equipment assembly. For

WORK EQUIPMENT.
2. Remove the counterweight assembly. For

COUNTERWEIGHT.
3. Disconnect 4 boom cylinder hoses (1).

a Plug the hoses to stop oil. 6. Disconnect 7 hoses (5) – (11).
• (5): Center swivel joint (Port D) – Swing mo-
tor (Port T)
• (6): Center swivel joint (Port D) – Hydraulic
tank
• (7): Center swivel joint (Port E) – Solenoid
valve
• (8): Center swivel joint (Port B) – Control
valve left travel (Port B2)
• (9): Center swivel joint (Port D) – Control
valve right travel (Port B5)
• (10): Center swivel joint (Port A) – Control
valve left travel (Port A2)
• (11): Center swivel joint (Port C) – Control
4. Sling boom cylinder assembly (2) temporarily. valve right travel (Port A5)
5. Remove plate (3) and pin (4) and lift off boom 7. Pull out pin (12) on the center swivel joint side
cylinder assembly (2). and disconnect the lock plate from the center
a Remove the boom cylinder on the opposite swivel joint.
side similarly.
4 Boom cylinder assembly: 360 kg
PC400/450(LC)-7 30-81
(2)
8. Remove 29 mounting bolts (13), leaving 3 each INSTALLATION

at the front and rear sides. • Carry out installation in the reverse order to
removal.
[*1]
•Match the soft zone point (P) of the outer
race and the soft zone point (S) of the inner
2 Mating face of swing circle:

race.
2 Threads of revolving frame mounting

bolt: Adhesive (LT-2)
9. Using a lever block, sling the revolving frame

assembly temporarily, balancing it in each direc-
tion.
a Put wood liners to the rear side of the frame.
• Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
a If the engine hood interferes with the sling,
erect the engine hood, referring to REMOV-
AL AND INSTALLATION OF RADIATOR
ASSEMBLY.
10. Remove the remaining 6 bolts and lift off revolv-

ing frame assembly (14). [*1]
k When removing the revolving frame assem-
bly, take care that it will not interfere with the
center swivel joint assembly.
4 Revolving frame assembly: 10,000 kg
30-82 PC400/450(LC)-7
(2)
3 Revolving frame mounting bolt 2. Tighten each bolt 208-25-71230 which is not
1. Tighten the bolts marked with A (at 4 places) marked with A according to above steps 1) – 3).
according to the following steps 1) – 3). If the tightening torque reaches 2,254 Nm {230
1) Tighten each bolt to 392 Nm {40 kgm} first. kgm} before completing the above steps and the
2) Then, tighten the bolt by 90° ± 5°. tightening angle is 35° – 95°, however, stop
• Make a mark on the bolt head with a tightening.
marker pen (to check the angle).
3) The tightening torque of the bolt tighten in 2)
above must be 1,176 Nm {120 kgm} or
larger.
a Marks P and S are the soft zone points.

• Bleeding air
Bleed air from the travel motor. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
PC400/450(LC)-7 30-83
(2)
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHT

ASSEMBLY
1. Set eyebolt [1] to counterweight assembly (1). • Carry out installation in the reverse order to
removal.
2. Remove 4 mounting bolts (2). [*1] a If heat insulation cover (3) of the engine com-
a Check where shims have been used. partment is flattened, replace it.

3. Lift off counterweight assembly (1). [*2] [*1]
a When lifting off the counterweight, take care
3 Mounting bolt:
not to strike it against the engine, radiator Adhesive (LT-2)
and cooler assembly, etc.
4
3,430 – 4,212 Nm {350 – 430 kgm}
Counterweight assembly: 9,500 kg
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the
exterior parts (horizontal clearance) with
shims.
• Kinds of shim thickness: 0.5 mm, 1
mm
2) Insert the shims so that the clearance
between the door and counterweight
and that between the revolving frame
and counterweight will be 10 ± 5 mm
evenly.
30-84 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL 7. Disconnect drain hoses (8), (9), and (10).

1. Remove 3 lower covers (1).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).
2. Drain the oil from the hydraulic tank.
6 Capacity of hydraulic tank:

Approx. 335 l 10. Remove sensor (13).
3. Open engine hood (2) and remove control valve 11. Disconnect suction tube (14).
top cover (3).
12. Sling the hydraulic tank assembly temporarily
and remove 6 mounting bolts (15).
5. Disconnect drain hoses (5) and (6). 13. Lift off hydraulic tank assembly (16).
6. Disconnect block (7). 4 Hydraulic tank assembly: 200 kg
PC400/450(LC)-7 30-85
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION
removal.


Approx. 335 l
Quantity of oil in tank (Center of oil
level gauge): 248 l
• Bleeding air
from each part.
30-86 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP

ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
796-460-1210 Oil stopper q 1

C
796-770-1320 Adapter q 1
REMOVAL
k Disconnect the cable from the negative (–) ter- 3. Drain the oil from the flywheel housing.
k Lower the work equipment to the ground and 4. Open the main pump side cover.
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure 5. Open the engine hood.
of the hydraulic tank.
a Put tags to the disconnected hoses and tubes to 6. Lift off covers (2) and (3) together.
1. Remove 2 lower covers (1).
8. Remove stay (5).
2. Remove the hydraulic tank strainer. Using tool

C, stop the oil.
a When not using tool C, remove the drain plug
to drain the oil from the hydraulic tank and
piping.
6 Hydraulic tank: Approx. 335 l
PC400/450(LC)-7 30-87
(2)
9. Disconnect the following 2 pump wiring connec- 11. Sling hydraulic pump assembly (18) temporarily
tors. and remove 12 mounting bolts (17).
• (6): V22 (PC-EPC solenoid valve)
Band color: Red
• (7): V21 (LS-EPC solenoid valve)
Band color: White
10. Disconnect the following 10 hoses and 1 tube.

• (8): EPC basic pressure port hose
• (9): Rear pump pressure input port hose
(Band color: Red)
• (10): Rear pump discharge port hose
• (11): Front pump discharge port hose
• (12): Drain port hose
• (13): Front load pressure input port hose 12. Lift off hydraulic pump assembly (18). [*1]
• (14): Rear load pressure input port hose
(Band color: Red) 4 Hydraulic pump assembly: 255 kg
• (15): Front pump pressure input port hose
• (16): Pump suction port tube
30-88 PC400/450(LC)-7
(2)
INSTALLATION
removal.
2 Hydraulic pump involute spline:

[*1]
2 Mating face of hydraulic pump case:

Anti-friction compound (LM-G)
3 Flywheel housing drain plug:

42.1 – 70.6 Nm {4.3 – 7.2 kgm}



Approx. 335 l
Quantity of oil in tank (Center of oil
level gauge): 248 l
• Bleeding air
from each part.
PC400/450(LC)-7 30-89
(2)
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC

PUMP INPUT SHAFT
1. Remove the hydraulic pump assembly. Refer to • Install in reverse order of removal.
t h e R E M O VA L O F H Y D R A U L I C P U M P
2 Oil seal lip portion: Grease (G2-LI)

ASSEMBLY section. [*1]
2. Remove snap ring (1) and then remove spacer 2 Oil seal outer circumference:
(2). Grease (G2-LI)
a Coat the oil seal outer circumference thinly
3. Pry off oil seal (3) with a screwdriver. [*1] with grease.
a When attempting to pry off the seal, do not a Press-fit oil seal (3), using tool .
damage the shaft.
30-90 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVAL
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank and set the safety lock lever
to the LOCK position..
a Put tags to the disconnected hoses and tubes to
1. Open engine hood (1).
2. Remove control valve top cover (2).
6. Disconnect the following 4 control valve hoses:

• (16): Port PPS1 hose (Front pump)
• (17): Port PLS2 hose (Hose band: Red)
• (18): Port PLS1 hose
• (19): Port PX1 hose (Hose band: Blue)
7. Remove relay bracket (20) and clamp (21).
8. Disconnect drain hose (22). (To tank)
9. Disconnect the following 6 left PPC hoses.

• (23): In order from top
3. Remove partition covers (3), (4), and (5) Bucket CURL (Hose band: White)
between the engine and control valve. Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm DUMP (Hose band: Yellow)
4. Remove the control valve bottom cover.
5. Disconnect the 2 wiring connectors and 8

hoses.
• (6): A51 (Front pump pressure sensor)
• (7): A52 (Rear pump pressure sensor)
• (8): Port PS hose (Hose band: Yellow-Blue)
• (9): Port PST hose (Hose band: Brown)
• (10): Port PPS2 hose (Rear pump, red)
• (11): Port PR hose (Solenoid)
• (12): Port PR hose (Pump, yellow)
• (13): Port PP1 hose (Front pump)
• (14): Port PP2 hose (Rear pump)
• (15): Port T hose (Oil cooler)
PC400/450(LC)-7 30-91
(2)
10. Disconnect 4 boom hoses (24). 15. Disconnect the following 6 right PPC hoses.
• (30): Bucket DUMP (Hose band: Black)
11. Remove boom tube clamps (25) and (26). • (31): Left travel FORWARD
(Hose band: Red)
• (32): Boom LOWER (Hose band: Brown)
• (33): Right SWING
• (34): Right travel FORWARD
(Hose band: Green)
• (35): Arm IN (Hose band: Blue)
12. Disconnect port TSW hose (27) (Swing motor

port S).
13. (28): In order from top

Remove port A-1 tube (Boom Hi bottom side).
Remove port A1 tube (Bucket bottom side).
Disconnect port A2 hose (Swivel joint port A). 16. Disconnect the following 3 control valve hoses.
After removing the hoses from ports B, remove a Do not disconnect hose C.
port A3 tube (Boom bottom side). • (36): Port BP5 hose (To solenoid)
Remove port A4 hose (Swing motor port MB). • (37): Port PX2 hose
Disconnect port A5 hose (Swivel joint port C). • (38): Port TS hose
Remove port A6 tube (Arm head side).
14. (29): In order from top

Disconnect port B-1 hose (Arm Hi bottom side).
Disconnect port B1 hose (Bucket head side).
Disconnect port B2 hose (Swivel joint port B).
Remove port B3 tube (Boom head side).
Remove port B4 hose (Swing motor port MA).
Disconnect port B5 hose (Swivel joint port D).
Remove port B6 tube (Arm bottom side).
30-92 PC400/450(LC)-7
(2)
17. Sling control valve assembly (40) temporarily INSTALLATION

and remove 3 mounting bolts (39). • Carry out installation in the reverse order to
removal.

• Bleeding air
from each part.
18. Lift off control valve assembly (40).
4 Control valve assembly: 250 kg
PC400/450(LC)-7 30-93
(2)
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY

a Only precautions for assembling the pressure REPLACEMENT PROCEDURE FOR PRES-
compensation valve assembly and control valve SURE COMPENSATION VALVE SEAL
assembly are explained below. a Since there many types of the pressure compen-
sation valves, make a mark on each valve to in-
SPECIAL TOOLS dicate from where it was removed.
New/Remodel
1. Remove piston (2), plug (3), and spring (4) from
Necessity
Symbol
Sketch
pressure compensation valve (1).
Q’ty
Part No. Part Name
2. Remove seal (5) and O-ring (6) from piston (2).
796-946-1310 Guide 21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide 20.9
1 1
(For 723-46-44100)
796-946-2210 Guide 20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide 21.6
1 a There many types of the pistons.
(For 723-46-42800) a Clean the pressure compensation valve
2
796-946-2120 Guide thoroughly. Then, using the tool, install seals
L 1 as shown in the figure.
(For 723-46-44100)
796-946-2220 Guide 3. Fit O-ring (6) to piston (2).
1
(For 723-46-45100, 723-46-45500)
4. Set tool L1 to piston (2) and push it in with your
796-946-1330 Sleeve hand slowly so that seal (5) will expand evenly.
1
(For 723-46-40100, 723-46-40601) a You may push in the seal to the flat part of
the tool first, and then install the tool to the
796-946-1430 Sleeve piston and push in the seal further.
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
30-94 PC400/450(LC)-7
(2)
5. Set tool L2 to piston (1) for other seal (3) and ASSEMBLY
push it in with your hand slowly so that seal (3) • 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 • 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) toward
piston and push in the seal further. cylinder ports (9) and (12).
6. Install correcting tool L3 to piston (1) for about 1

minute to fit seals (2) and (3).
a Check that the seal are not projected or bro-
ken.
• Install filters (13) to the bottom of ports PLS1

and PLS2 as shown below.
7. Fit plug (3) and spring (4) to piston (2) and

assemble pressure compensation valve (1).
a If these parts are difficult to install, do not
push them in forcibly, but install them to cor-
recting tool L3 to fit the seals, and then install
them to the piston.
a After assembling, push the piston with your
hand and check that it is returned by only the
spring force.
PC400/450(LC)-7 30-95
(2)
3 Mounting bolt of boom Hi check valve,

quick return valve, lock valve, and arm
plate: 58.8 – 73.6 Nm {6 – 7.5 kgm}
2 Mating faces of control valve top and

• Control valve top and bottom covers
bottom covers:
SEALEND 242 or equivalent
a Use 2 washers (W2) each for only 2 places
of the control valve top cover.
• Tighten the mounting bolts of the control valve
top and bottom covers in the following order.
(A o D o C o B)
3 Mounting bolt of control valve top and

bottom covers:
156.9 – 176.5 Nm {16 – 18 kgm}
• Merge-divider valve
2 Mating face of merge-divider valve:

SEALEND 242 or equivalent
• Tighten the mounting bolts of the merge-divider

valve similarly to those of the control valve cov-
ers.
3 Mounting bolt of merge-divider valve:

156.9 – 176.5 Nm {16 – 18 kgm}
• Tighten the mounting bolts of the boom Hi check

valve, quick return valve, lock valve, and arm
plate similarly to those of the control valve cov-
ers.
30-96 PC400/450(LC)-7
(2)
3 Mounting bolts of back-pressure valve,

boom Hi check valve, quick return
valve, lock valve and arm plate:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Pressure compensation valve

a When installing each pressure compensa-
tion valve, check the mark made when it was
removed.
• Main relief valve assembly

After installing the main relief valve to the control
valve, see TESTING AND ADJUSTING, Testing
and adjusting oil pressures in work equipment,
swing, and travel circuits.
PC400/450(LC)-7 30-97
(2)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

ASSEMBLY
REMOVAL 3. Pull out pin (16) on the side of center swivel joint
k Replace the remaining pressure in the hydraulic and remove the jam plate from the center swivel
circuit. For details, see TESTING AND AD- joint.
JUSTING, release of remaining pressure in hy-
draulic circuit.
a Mark all the piping with tags to prevent mistakes
in the mounting position when installing.
1. Disconnect six hoses (1) through (6) between

travel motor and center swivel joint.
• (1): Center swivel joint (T port) – Left travel
motor (T port)
• (2): Center swivel joint (T port) – Right trav-
el motor (T port)
• (3): Center swivel joint (B port) – Left travel
motor (PA port)
• (4): Center swivel joint (D port) – Right trav- 4. Remove four mounting bolts (17).
el motor (PB port)
• (5): Center swivel joint (A port) – Left travel
motor (PB port)
• (6): Center swivel joint (C port) – Right trav-
el motor (PA port)
5. Remove center swivel joint assembly (18). [*1]
4 Center swivel joint assembly: 40 kg
2. Disconnect nine hoses (7) through (15).

• (7): Center swivel joint (E port) – Left travel
motor (P port)
• (8): Center swivel joint (E port) – Right trav-
el motor (P port)
• (9): Center swivel joint (D port) – swing mo-
tor (T port)
• (10): Center swivel joint (D port) – Hydraulic
tank
• (11): Center swivel joint (E port) – solenoid
valve
• (12): Center swivel joint (B port) – Left travel
control valve (B2 port)
• (13): Center swivel joint (D port) – Right trav-
el control valve (B5 port)
• (14): Center swivel joint (A port) – Left travel
control valve (A2 port)
• (15): Center swivel joint (C port) – Right trav-
el control valve (A5 port)
30-98 PC400/450(LC)-7
(2)
INSTALLATION
• Install in reverse order of 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)
• Refilling with oil (hydraulic tank)

system. Then check the oil level again.
• Bleeding air
Bleed the air from the travel motor. For details
see TESTING AND ADUSTING, Air Bleeding of
Various Parts.
PC400/450(LC)-7 30-99
(2)
DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT

ASSEMBLY
SPECIAL TOOLS 1. Remove cover (1).
New/Remodel
2. Remove snap ring (2).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name 3. Using tool M, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove seal (6) from swivel shaft (5).

790-101-2501 Push puller q 1
• 790-101-2510 • Block 1 5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
M • 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
DISASSEMBLY
ASSEMBLY
1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer to
2 Contact surface of rotor, shaft:

install.
Grease (G0-LI or G2-LI)

a When installing the rotor, be extremely care-
ful not to damage the slipper seal and the O-
ring.
4. Install ring (3) ans secure with snap ring (2).
3 Mounting bolt:
5. Install O-ring and cover (1).
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
30-100 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VELVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

VELVE ASSEMBLY
a Only precautions for assembling the work equip- a When installing pistons (8), apply grease to
ment PPC valve assembly are explained below. their outside and the inside of the valve body
3 Mounting bolt of plate (5):

holes.
2 Sliding parts of joint (4):

11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Female threads of body (A):

2 – 4 cc of Grease (G2-LI)
Adhesive (LT-2)
a Apply a drop (about 0.02 g) of LOCTITE to

each of the 2 threaded parts of the body as
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}

shown in the figure, and then tighten joint (4).
a Observe the tightening torque of the joint.
2 Contact parts of piston and disc

ASSEMBLY
3 Nut (1): 69 – 88 Nm {7 – 9 kgm}
(2): Grease 0.3 – 0.8 cc (G2-LI)
• Work equipment PPC valve assembly
a Install springs (11 ) with the small-diameter
(inside diameter) end on the shim (12) side. a When installing disc (2), adjust the play to
a Springs (10 ) having different number of 0.5 – 3mm at 200 mm from the turning center
turns are used for the following hydraulic of the lever.
ports. Take care when installing them.
Installed height: 31.9 mm (Common to all
springs)
Installed load:
P1, P2: 35.3 N {3.6 kg}
P3, P4: 21.6 N {2.2 kg}
a The position of each port is stamped on the
2 Piston (8): Grease (G2-LI)

underside of valve body.
PC400/450(LC)-7 30-101
(2)
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY
DISASSEMBLY
a Only precautions for assembling the travel PPC
valve assembly are explained below.
ASSEMBLY
• Travel PPC valve assembly
a Insert shim (3) of the thickness and quantity
checked when disassembled.
Standard shim thickness: 0.3 mm
a Since spring (4) is not symmetric vertically,
install it with the small-diameter (inside diam-
eter) end on the shim side.
2 Periphery of piston (7) and inside
2 Sliding part of shaft (13) (4 – 8 cc),

of hole of body (1): Grease (G2-LI)
contact parts of lever (12) and pis-

ton (7), and contact part of pin of
lever (26) and plate (24) (0.3 – 0.8
cc): Grease (G2-LI)
a Use the inserting jig described in

KES.D.07177 to insert bushing (19).
a Use the inserting jig described in
KES.D.04025 to insert spring pin (25).
30-102 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY
DISASSEMBLY
SPECIAL TOOLS 1. Piston rod assembly
1) Remove the piping from the cylinder assem-
New/Remodel
bly.
Necessity
Symbol
2) Remove the mounting bolts and disconnect
Sketch
Q’ty
Part No. Part Name cylinder head assembly (1).
3) Pull out piston rod assembly (2).
a Put a container under the cylinder to re-
Cylinder repair ceive oil.
1 790-502-1003 t 1
stand
Wrench assem-
790-102-4300 t 1
2 bly
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
07281-01589 boom and q 1
4
bucket)
796-720-1690 Ring (For arm) q 1
4) Disassemble the piston rod assembly
07281-01919 Clamp (For arm) q 1 according to the following procedure.
790-201-1702 Push tool kit t 1 i) Set piston rod assembly (2) to tool N1.
• Push tool
• 790-201-1851 1
N (For bucket)
• Push tool
• 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 1
• 790-101-5021 • Grip 1
ii)
Remove piston assembly lock screw
• 01010-50816 • Bolt 1 (3).
a This work is common to the boom, arm,
6 • 790-201-1660 • Plate 1
(For bucket) and bucket cylinders.
Screw size: M12 x Pitch 1.75
• Plate
• 790-201-1670 1
(For boom)
• Plate
• 790-201-1680 1
(For arm)
PC400/450(LC)-7 30-103
(2)
a If screw (3) is so caulked that you cannot vii) Remove cap (8), 11 balls (9), and
remove it, tighten it temporarily and tap plunger (10).
the threads on it, and then remove it. • Perform this work for only the arm
cylinder.
a Since cap (8) is made of nylon, tight-
en a screw into it and pull it with pli-
ers.
iii) Using tool N2, remove piston assembly

(4).
• When not using tool N2, loosen the
piston assembly by using the drilled
holes (Ø10: 2 places) (in which the 2. Disassembly of piston assembly
pins of N2 are inserted in the follow- 1) Remove rings (11).
ing figure). 2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove the O-ring and backup rings (14).
iv) Remove plunger (5).

• Perform this work for only the boom
and arm cylinder. 3. Disassembly of cylinder head assembly
v) Remove collar (6). 1) Remove the O-ring and backup ring (15).
• Perform this work for only the boom 2) Remove snap ring (16) and dust seal (17).
and arm cylinder. 3) Remove rod packing (18).
vi) Remove head assembly (7). 4) Remove buffer ring (19).
5) Remove snap ring (21).
6) Remove bushing (20).
30-104 PC400/450(LC)-7
(2)
ASSEMBLY 2. Assembly of piston assembly

a Take care not to damage the packings, dust 1) Using tool N3, expand piston ring (13).
seals, O-rings, etc. a Set piston ring (13) to tool N3 and turn
a Clean the all parts. After installing them, cover the handle 8 – 10 times to expand the
the piping ports and pin holes to prevent dirt from piston ring.
entering. 2) Set tool N4 and contract piston ring (13).
a Do not insert each backup ring forcibly, but warm
it in water at 50 – 60°C and then insert it.
3) Install backup ring and O-ring (14).

4) Install wear ring (12).
1. Assembly of cylinder head assembly 5) Install ring (11).
1) Using tool N5, press fit bushing (20). a Do not increase the closed gap of the
2) Install buffer ring (19). ring too much.
2 Ring groove: Grease (G2-LI)

3) Install rod packing (18).
4) Using tool N6, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).
6) Install snap ring (21).
PC400/450(LC)-7 30-105
(2)
3. Piston rod assembly 6) Assemble piston assembly (4) according to

1) Set the piston rod to tool N1. the following procedure.
2) Install cylinder head assembly (7) to the pis- • When reusing the rod and piston as-
ton rod. sembly (4)
3) Fit the O-ring and backup ring to collar (6), i) Tighten piston assembly (4). Then,
and then install them. using tool N2, tighten piston assembly
• Perform this work for only the boom and (4) until the screw holes are aligned.
arm cylinders. a Remove the burrs from the threads
4) Install plunger (5). with a file.
• Perform this work for only the boom and Go to iv).
arm cylinders.
• When replacing either or both of the

5) Set plunger (10) to the piston rod. Install 11 rod and piston assembly (4) with new
balls (9) and secure them with cap (8). ones
a After installing the plunger, check that it a Make a mark of the cushion plug position
has a little play at its end. on the end of the rod having the bottom
• Perform this work for only the arm cushion.
cylinder. • Perform this work for only the arm
cylinder.
ii) Using the tool, tighten piston assembly
(4) until it reaches the end of the rod.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check
that plunger (5) has some play.
• Perform this work for only the boom
and arm cylinders.
30-106 PC400/450(LC)-7
(2)
iii) Make a screw hole to install screw (3). 7) Install piston rod assembly (2).
a Apply a drill to the V-groove of the a Set the abutment joint of the ring at a
threaded parts of piston (4) and rod side and insert the piston rod, aligning it
(2) and make a hole. with the cylinder tube.
a When making a hole on the cylinder a After inserting the piston rod, check that
(arm cylinder) having the bottom the ring is not broken or removed, and
cushion, make it around the cushion then insert to the end.
plug.
• Dimensions of screw hole (mm)
Tap drill diameter Tap to be used

10.3 12 x 1.75
Tap drill Tapping

hole depth depth
Bucket/Boom 27 20
Arm 36 29
iv) Tighten screw (3).

a Clean the parts thoroughly and re- 8) Tighten the mounting bolts of cylinder head
move metal chips, dirt, etc. assembly (7).
2 Threads of screw: 3 Mounting bolt:
3 Screw:
Adhesive (LOCTITE No. 262)
Cylinder
Tightening torque
name
58.9 – 73.6 Nm {6 – 7.5 kgm}
v) Caulk the threaded part by 4 places Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm}
with a punch. Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54.0 ± 8 kgm}
9) Install the piping.
PC400/450(LC)-7 30-107
(2)
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT

ASSEMBLY
SPECIAL TOOLS 4. Start the engine and retract the piston rod.
a Bind the rod with wires, etc. so that it will not
New/Remodel
be extracted and lower it onto a stand or put
Necessity
a wood block to the bottom side so that the
Symbol
Sketch
Q’ty
Part No. Part Name cylinder will not lower. When putting the
wood block, remove the grease fitting on the
bottom side.
a Disconnect the boom cylinder on the oppo-
796-670-1100 Remover q 1
site side similarly.
• 796-670-1110 • Sleeve 1 a When slinging the boom cylinder, if the sling
interferes with the work equipment lamp, re-
• 796-670-1120 • Plate 1
move the work equipment lamp.
• 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).
Puller (490 kN a Put oil stopper plugs and secure the hoses to
790-101-4000 q 1 the valve side with ropes.
{50t}, long)
Pump (294 kN
790-101-1102 q 1
{30t})
REMOVAL
k Extend the arm and bucket fully, lower the work
equipment to the ground, and set the safety lock
k See TESTING AND ADJUSTING, Releasing re-
sidual pressure in hydraulic circuit.
1. Disconnect grease hose (1).

7. Sling work equipment assembly (12) tempo-
2. Sling boom cylinder assembly (2) temporarily
rarily.
and remove lock bolt and nut (3). [*1]
8. Remove cover (9), plate (10), and foot pin (11)
3. Remove plate (4) and head pin (5). [*2]
to disconnect work equipment assembly (12).
a Check the quantity and positions of the in-
[*3]
serted shims.
30-108 PC400/450(LC)-7
(2)
• When removing with tool P INSTALLATION

Remove plate (10). Sling and set tool P and • Carry out installation in the reverse order to
remove foot pin (11) to disconnect work removal.
equipment assembly (12).
a Check the quantity and positions of the in- [*1]
serted shims. a Tighten the locknut so that clearance "a" be-
tween the plate and nut will be 0.5 – 1.5 mm.
9. Move the machine in reverse to remove work
2 Inside wall of bushing before assem-

equipment assembly (12). [*2]
4 Work equipment assembly: bling pin:
2 Greasing after assembling pin:

PC400-7, PC400LC-7: 7,400 kg Anti-friction composition (LM-P)
PC450-7, PC450LC-7: 8,400 kg
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance
"b" between cylinder rod (12) and plate (4)
will be 1.5 mm or less.
Standard shim: 1.0, 2.0 mm
PC400/450(LC)-7 30-109
(2)
2 Inside wall of bushing before assem-

[*3]
bling pin:
2 Greasing after assembling pin:

Anti-friction composition (LM-P)
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance
"c" between boom (13) and bracket (14) will
be 1 mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
• Bleeding air
from each part.

30-110 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS

(STUCK GLASS)
a Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) – (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
PC400/450(LC)-7 30-111
(2)
SPECIAL TOOLS (The figure shows the operator's cab of a

wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced ac-
cording to the following procedure.
a If the window glass is broken finely, it may be
removed with knife [4] and a screwdriver.
1. Using seal cutter [1], cut the adhesive between
a Widening the cut with a screwdriver, cut the
broken window glass (7) and operator's cab
adhesive and both-sided adhesive tape with
(metal sheet) (8).
knife [4].
(The figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
2. Remove the window glass.
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the friction-
al heat, apply lubricant to it.
30-112 PC400/450(LC)-7
(2)
INSTALLATION 3. Apply primer (10).

1. Using a knife and scraper [5], remove the a The using limit of primer (10) is 4 months af-
remaining adhesive and both-sided adhesive ter the date of manufacture. Do not use prim-
tape from the metal sheets (glass sticking sur- er (10) after this limit.
faces) of the operator's cab. a Use the primer within 2 hours after unpack-
a Remove the adhesive and both-sided adhe- ing it.
sive tape to a degree that they will not affect a Even if the primer is packed again just after
adhesion of the new adhesive. Take care it is unpacked, use it within 24 hours after it
not to scratch the painted surfaces. (If the is unpacked for the first time. (Discard the
painted surfaces are scratched, adhesion primer 24 hours after it is packed.)
will be lowered.) 1) Stir the primers for paint and glass suffi-
ciently before using them.
(The figure shows the operator's cab of a a If the primer has been stored in a refrig-
wheel loader.) erator, leave it at the room temperature
for at least half a day before stirring it. (If
the primer is unpacked just after taken
out of the refrigerator, water will be con-
densed. Accordingly, leave the primer at
the room temperature for a sufficient
time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a

wheel loader.)
PC400/450(LC)-7 30-113
(2)
3) Evenly apply paint primer to the surfaces to a In addition to the above parts, apply the
stick both-sided adhesive tapes and the sur- primer to right side window glass (1) and
faces out of those surfaces on operator's door lower window glass (3).
cab (8) which will be coated with the adhe- • Range to apply primer additionally for
2 Paint primer:
sive. right side window glass (1): (b)
• Range to apply primer additionally for
SUNSTAR PAINT PRIMER door lower window glass (3): (c)
580 SUPER or equivalent a After applying the primer, leave it for at
a Do not apply the primer more than 2 least 5 minutes (within 8 hours) to dry.
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the

primer all over dimension (a).
• Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass

primer is applied by mistake, wipe it off
with white gasoline.
30-114 PC400/450(LC)-7
(2)
4) Evenly apply glass primer to the sticking 4. Stick both-sided adhesive tape (6) along the
2 Glass primer:
surfaces of window glass (9). inside edge of the glass sticking section.
a Do not remove the release tape of the both-
SUNSTAR GLASS PRIMER sided adhesive tape on the glass sticking
580 SUPER or equivalent side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive tape,
times. (If it is applied more than 2 times, do not touch the cleaned surface as long as
its performance will be lowered.) possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window
glass (9) and all over dimension (d) a When sticking both-sided adhesive tape (6)
which will be on both-sided adhesive around a frame, do not lap its finishing end
tape (6) and operator's cab (8). over the starting end but make clearance e of
a Do not apply the primer to the boarder about 5 mm between them.
about 5 mm wide between the black part 1) Stick both-sided adhesive tape (6) for right
and transparent part of the glass. side window glass (1) as shown in the fig-
a After applying the primer, leave it for at ure.
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
PC400/450(LC)-7 30-115
(2)
a Stick both-sided adhesive tape (6a) addition- a Stick both-sided adhesive tape (6b) ad-
ally for right side window glass (1). ditionally for door lower window glass
• Positions to stick additional both-sided adhe- (3).
sive tape for right side window glass: a Positions to stick additional both-sided
(f) : 50 mm adhesive tape for door lower window
(g) : 90 mm glass:
(h) : 250 mm (j) : 110 mm
(k) : 90 mm
(m) : 200 mm
2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the
figure. 4) Stick both-sided adhesive tape (6) for front
window glass (4) as shown in the figure.
3) Stick both-sided adhesive tape (6) for door

lower window glass (3) as shown in the fig- a Stick both-sided adhesive tape (6c) of
ure. the lower side of the front window glass
along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the in-
side, it will be seen through the
transparent part of the glass.)
30-116 PC400/450(LC)-7
(2)
5. Position the new window glass. a When positioning front window glass (4),
1) Check the clearance between the window set its horizontal position to the frame
glass and the operator's cab on the right, width and set its vertical position so that
left, upper, and lower sides, and then adjust height difference (p) between it and the
it evenly. frame top will be 3 mm.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning
line n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator's cab before in-
stalling the window glass.
6. Apply adhesive.
2 Adhesive (Summer):
a Use either of the 2 types of the adhesive.
SUNSTAR PENGUINE
2 Adhesive (Winter):
SEAL 580 SUPER "S"
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the noz-
zle.
PC400/450(LC)-7 30-117
(2)
2) Cut the tip of the adhesive nozzle (14) so a Apply adhesive (15) to dimensions (s)
that dimensions (q) and (r) will be as fol- and (t) of both-sided adhesive tape (6) of
lows. operator's cab (8).
• Dimension (q): 10 mm • Dimension (s) : 10 mm
• Dimension (r) : 15 mm • Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) additionally for ad-
ditional both-sided adhesive tape (6a) of
the right side window glass and addition-
al both-sided adhesive tape (6b) of door
lower window glass.
4) Remove the release tape of the both-sided

adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab.
30-118 PC400/450(LC)-7
(2)
7. Install the window glass. a After installing front window glass (4), fill
1) Install window glass (9), matching it to the the clearances between it and center
lines of the positioning tapes drawn in step trim seal (16) with caulking material in
5. range (s) to dimensions (t) and (u).
a Since the window glass cannot be re- After applying the primer to glass (4) of
moved and stuck again, stick it very section A – A, apply adhesive as caulk-
carefully. ing material.
a Stick the glass within 5 minutes after ap- • Caulking dimension (t) : 2 mm
plying the adhesive. • Caulking dimension (u) : 5 mm
2) After sticking window glass (9), press all a When caulking, mask the glass side and
around it until it is stuck to the both-sided form the adhesive with a rubber spatula
adhesive tape. as shown in the figure.
2 Glass primer:
a Press the corners of the window glass a Wipe off projected adhesive.
firmly.
SUNSTAR GLASS
2 Adhesive:
PRIMER 580 SUPER
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
a You can perform this work efficiently by

pulling window glass (9) from inside of
the operator's cab with suction cup Y1.
PC400/450(LC)-7 30-119
(2)
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator's cab
operator's cab, insert stopper rubbers Y2 to and window glass.
2 places (v) at the bottom of the glass to fix a Using white gasoline, wipe off the adhesive
the glass. before it is dried up.
a When cleaning the glass, do not give an im-
pact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
30-120 PC400/450(LC)-7
(2)
DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY

k Lower the work equipment to the ground and 5. Release the rear locks.
stop the engine.
a To replace the front window glass, the front win- 6. Lower the front window assembly carefully a lit-
dow assembly must be removed from the opera- tle. Put out rollers (8) and (9) under the both
tor's cab. The procedure for removing and sides of the front window through the portion
installing the front window assembly (front frame from which the corner blocks were removed in
and front window glass) is explained below. step 3 (the portion where the rail is open) and
hold them.
REMOVAL
1. Raise the front window assembly to the ceiling 7. Remove rollers (8) and (9) under the both sides
and fix it with the rear locks (on both sides). of the front window.
2. Remove left corner blocks (1) and (2) and right

corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block
bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.
a This bolt will be used to hang the pull-up as-
sist cable in step 8.
PC400/450(LC)-7 30-121
(2)
8. Remove left lower pin (10). [*3] 10. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) at a Do not let the front window assembly touch
the end of pull-up assist cable (11) comes the monitor.
off.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied to
the rear of the operator's cab. Accordingly,
take care when removing left lower pin (10)
to disconnect pull-up assist cable (11).
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front win-
dow assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower it
gradually.
30-122 PC400/450(LC)-7
(2)
INSTALLATION

removal.
[*1] [*2]
• Adjust opening and closing of the front window
assembly according to the following procedure.
1. Open and close the front window to check that it

does not interfere with the rails and the rollers
are not hitch.
2. If there is any problem in opening or closing of

the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
3 Mounting bolt: 98 Nm {1.0 kgm}

then tighten the mounting bolts again.
PC400/450(LC)-7 30-123
(2)
3. Raise the front window assembly and fix it with 5. Install left corner blocks (1) and (2) and secure
the rear locks (on both sides). left corner bracket (6) with left striker bolt (4).
a Check that the locks in the rear of the opera- a Tighten the striker bolt securely after adjust-
tor's cab are applied securely. ing it in step 6.
a Install the left corner blocks so that there will
4. Install right corner block (3) and fix right corner be no level difference at 2 part (d).
block bracket (7) with right striker bolt (5). a Secure roller clearance (e).
a Tighten the striker bolt securely after adjust-
ing it in step 6.
a Install the right corner block so that there will
be no level difference at part (a).
a Install the right corner block so that level dif-
ference (b) between the rail and right corner
block (3) at part PF will be 0 – 1.0 mm.
Check that the right corner block is not pro-
jected from the rail at the rolling surface of
the roller.
a Secure roller clearance (c) at part PJ.
30-124 PC400/450(LC)-7
(2)
6. Adjust the striker bolts according to the following 2) Open and close the front window assembly
procedure (Adjust the "CLOSE" positions of the and check the working condition of both
front window assembly locks). locks (20) and (21).
1) Tighten left striker bolt (4) and right striker i) If both locks do not work normally, move
bolt (5) at roughly right positions so that the striker bolts toward the rear of the
front window glass (18) will be fitted to cab- cab and tighten them again.
side trim seal (19). ii) After moving the striker bolts, check the
fitness of the front window glass and
cab-side trim seal which was checked in
step 6.
iii) Repeat the work in i) and ii) until the fit-
ness of the front window and the work-
ing condition of both locks (20) and (21)
are acceptable, and then tighten the
striker bolts.
7. After adjusting the striker bolts, splash water

heavily over the front window glass and check
that the water does not leak into the cab.
PC400/450(LC)-7 30-125
(5)
8. Adjust the "opening" lock of the front window 9. Adjust the front window stoppers.
assembly. 1) After adjusting "closing" lock of the front win-
1) After adjusting the "closing" lock of the front dow assembly in step 9, check the contact
window in step 6, raise the front window of both front window stoppers (23).
assembly to the ceiling. 2) If both stoppers (23) do not contact nor-
2) Set the right and left front window assembly mally, adjust and fix them at places where
locks at the rear of the operator's cab to the they contact normally.
"OPEN" positions, and then check the fol-
lowing items.
• Check that right and left locks (20) and
(21) are closed normally.
• Check that right and left locks (20) and
(21) are inserted in parallel in right and
left striker plates (22).
• Check that right and left rubber stoppers
(24) are in contact with the front window
assembly and their deflection allowance
is 1.5 – 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera- 10. Check the latching effort of the front window
tor's cab. assembly.
1) After finishing steps 6 – 9, check that latch-
ing efforts of both locks (20) and (21) are
even.
a Check the latching efforts on both "clos-
ing" side (in the front of the operator's
cab) and "opening" side (in the rear of
the operator's cab).
3 Left lower pin:

[*3]
27 – 34 Nm {2.75 – 3.47 kgm}

2 Mounting bolt: Adhesive (LT-2)
30-126 PC400/450(LC)-7
(5)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/2).....................................................................................................90- 3

HYDRAULIC CIRCUIT DIAGRAM (2/2).....................................................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/6) ...................................................................................................90- 7
ELECTRICAL CIRCUIT DIAGRAM (2/6) ...................................................................................................90- 9
ELECTRICAL CIRCUIT DIAGRAM (3/6) ...................................................................................................90-11
ELECTRICAL CIRCUIT DIAGRAM (6/6) ...................................................................................................90-15-2
AIR CONDITIONER ELECTRICAL CIRCUIT ............................................................................................90-17
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE).....................................................90-19
PC400/450(LC)-7 90-1
(9)
HYDRAULIC CIRCUIT DIAGRAM (1/2)
PC400/450(LC)-7 90-3
HYDRAULIC CIRCUIT DIAGRAM (2/2)
PC400/450(LC)-7 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/6)
PC400/450(LC)-7 90-7
(8)
PC400/450(LC)-7 90-9
(9)
PC400/450(LC)-7 90-11
(8)
PC400/450(LC)-7 90-13
(8)
PC400/450(LC)-7 90-15
(8)
PC400/450(LC)-7 90-15-2
(8)
AIR CONDITIONER ELECTRICAL CIRCUIT
PC400/450(LC)-7 90-17
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) PC400, 450-7 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) PC400, 450-7
Connector No. of Connector No. of

Type Name of device Address Type Name of device Address
No. pins No. pins
A01 X 4 Intermediate connector T-1 M21 PA 9 Radio U-2
A02 X 4 Intermediate connector T-1 M22 Y090 2 Horn switch O-7
A03 DT 12 Intermediate connector N-2 M23 Y090 2 One-touch power maximizing switch T-1
A04 SWP 6 Intermediate connector O-1 M26 S 12 Intermediate connector W-4
A05 SWP 14 Intermediate connector T-1 M27 YAZAKI 18 Air conditioner unit W-4
A06 SWP 14 Intermediate connector O-1 M29 040 20 Air conditioner control panel U-2
A07 SWP 16 Intermediate connector S-1 M30 040 16 Air conditioner control panel U-2
A09 SWP 8 Intermediate connector N-2 M31 M 2 Optional power supply (2) W-7
A10 Terminal 1 Revolving frame grounding H-2 M32 M 2 Optional power supply (1) W-6
A11 Terminal 1 Revolving frame grounding I-2 M33 M 2 Optional power supply (3) V-9
A12 Terminal 1 Revolving frame grounding I-2 M33 SUMITOMO 4 Air conditioner unit W-4
A13 Terminal 1 Revolving frame grounding I-2 M34 X 1 Air conditioner compressor electromagnetic clutch I-9
A14 Terminal 1 Revolving frame grounding F-1 M37 Terminal 1 Horn switch (High tone) H-1
A15 Terminal 1 Revolving frame grounding J-3 M38 Terminal 1 Horn switch (Low tone) G-1
A16 Terminal 1 Revolving frame grounding J-3 M38 M 2 Machine push-up switch Q-8
A20 Terminal 1 Battery relay (Terminal E) D-1 M40 M 2 Working lamp Z-8
A21 Terminal 1 Battery relay (Terminal BR) D-2 M41 M 2 Working lamp (Additional) Y-7
A22 Terminal 1 Battery relay (Terminal N) F-2 M42 M 1 Intermediate connector H-9
A23 Terminal 1 Battery relay (Terminal B) F-2 M43 M 1 Working lamp (Rear) J-9
A31 D 2 Air cleaner clogging sensor H-9 M45 D 12 Intermediate connector W-7
A33 X 2 Radiator water level sensor H-9 M46 X 4 RS232C junction connector V-9
A34 L 2 Fusible link (65 A) D-2 M71 M 2 Room lamp AA-8
A35 M 2 Fusible link (30 A) G-9 M72 M 4 DC/DC converter U-2
A40 Terminal 1 Horn (Low tone) G-9 M73 M 2 Speaker (Left) AD-8
A41 Terminal 1 Horn (High tone) G-9 M79 M 2 12-V accessory outlet V-9
A42 M 1 Intermediate connector H-9 NE YAZAKI 2 Engine Ne sensor AJ-5
A43 D 2 Travel alarm J-3 OL DT 2 Engine oil level sensor AJ-3
A44 M 1 Right headlamp D-5 P01 070 12 Monitor panel N-6
A50 KES0 2 Windshield washer motor (Tank) L-5 P02 040 20 Monitor panel N-5
A51 D 3 F pump oil pressure sensor L-8 P03 M 2 Buzzer cancel switch Q-8
A52 D 3 R pump oil pressure sensor L-7 P05 M 2 Rotary lamp switch U-2
A60 X 1 Fuel level sensor G-9 P15 Y050 2 Air conditioner daylight sensor N-5
A61 D 2 Hydraulic oil temperature sensor L-5 P70 040 16 Monitor panel N-5
A70 D 3 Boom cylinder bottom pressure sensor for overload alarm H-1 PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2
A73 D 2 Fuel priming pump G-9 PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2
A80 DT 8 Intermediate connector S-1 PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2
AL/B Terminal 1 Alternator B terminal AE-6 PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1
AL/E Terminal 1 Alternator E terminal AE-6 PFUEL AMP 3 Common rail pressure sensor AJ-4
AL/R Terminal 1 Alternator R terminal AE-6 PIM SUMITOMO 3 Boost pressure sensor AJ-8
C01 DRC 24 Pump controller U-9 R10 R 5 Light relay P-7
C02 DRC 40 Pump controller U-9 R11 R 5 Starting motor cutout relay (PPC lock) P-8
C03 DRC 40 Pump controller W-9 R13 R 5 Starting motor cutout relay (Personal code) Q-8
C09 S 8 Model selection connector (Pump controller) W-9 R20 R 5 ATT circuit selector relay W-7
CB1 DRC 24 Pump controller I-9 R22 R 5 Power supply relay for engine controller W-6
CB2 DRC 40 Pump controller I-9 R30 R 5 Air conditioner blower relay W-4
CB3 DRC 40 Pump controller J-9 R31 R 5 Air conditioner compressor relay W-3
CB5 DT 8 Model selection connector (Engine controller) J-9 S01 D 4 Bucket CURL pressure sensor K-3
CN1 DT 2 No. 1 fuel injector AI-2 S02 X 2 Boom LOWER oil pressure switch L-2
CN2 DT 2 No. 2 fuel injector AI-3 S03 X 2 Swing RIGHT oil pressure switch L-2
CN3 DT 2 No. 3 fuel injector AJ-3 S04 D 3 Arm IN pressure switch K-3
CN4 DT 2 No. 4 fuel injector AJ-5 S05 X 2 Bucket DUMP oil pressure switch L-2
CN5 DT 2 No. 5 fuel injector AJ-6 S06 X 2 Boom RAISE oil pressure switch L-2
CN6 DT 2 No. 6 fuel injector AJ-6 S07 X 2 Swing LEFT oil pressure switch L-2
D01 SWP 8 Concentrated diode W-7 S08 X 2 Arm DUMP oil pressure switch L-1
D02 SWP 8 Concentrated diode W-5 S09 X 2 Service oil pressure switch (Intermediate connector) L-1
E06 M 3 Fuel control dial P-7 S10 X 2 Service front oil pressure switch K-1
ENE DT 2 Engine speed sensor AJ-5 S11 X 2 Service rear oil pressure switch L-1
ER02 HD30 31 Intermediate connector AF-8 S14 M 3 Safety lock lever switch S-1
ER03 HD30 31 Intermediate connector AF-8 S21 Terminal 6 Emergency pump drive switch R-9
F02 M 2 Rotary lamp AA-9 S22 Terminal 6 Swing holding brake release switch R-8
FB1 — — Fuse box V-2 S25 S090 16 Intermediate connector R-9
G YAZAKI 2 Engine G sensor AH-2 S30 X 2 Travel oil pressure switch P-1
GND DT 2 Joint connector (with diode) AJ-6 S31 X 2 Travel steering oil pressure switch P-1
GND2 Terminal 1 Engine grounding AJ-5 ST DT 2 Starting motor AF-7
GND3 Terminal 1 Engine grounding AE-7 ST/B Terminal 1 Starting motor B terminal AF-7
H08 M 8 Intermediate connector W-6 T05 Terminal 1 Floor frame grounding V-3
H09 S 8 Intermediate connector W-6 T06 Terminal 1 Radio body grounding S-9
H10 S 16 Intermediate connector T-9 T06A M 1 Intermediate connector T-2
H11 S 16 Intermediate connector S-9 T11 Terminal 1 Cab grounding
H12 S 12 Intermediate connector S-9 THL DT 3 Spill fuel temperature sensor AJ-4
H15 S090 20 Intermediate connector O-7 TWH DT 2 Engine water temperature sensor (High temperature) AE-7
HT/B Terminal 1 Heater relay B terminal AH-9 TWL DT 3 Engine water temperature sensor (Low temperature) AG-8
HT/S Terminal 1 Heater relay S terminal AJ-7 V01 DT 2 PPC oil pressure lock solenoid valve J-3
J01 J 20 Junction connector (Black) T-9 V02 DT 2 Travel junction solenoid valve J-2
J02 J 20 Junction connector (Black) T-9 V03 D 2 Merge-divider solenoid valve J-2
J03 J 20 Junction connector (Green) U-9 V04 D 2 Travel speed solenoid valve J-2
J04 J 20 Junction connector (Green) V-3 V05 D 2 Swing holding brake solenoid valve J-2
J05 J 20 Junction connector (Pink) V-3 V06 D 2 Machine push-up solenoid valve J-2
J06 J 20 Junction connector (Orange) W-3 V08 D 2 2nd-stage relief solenoid valve J-1
J07 J 20 Junction connector (Orange) W-5 V12 D 2 ATT return selector solenoid valve J-1
J08 J 20 Junction connector (Pink) W-5 V13 DT 2 Solenoid valve for bottom dump open L2
K19 M 2 Pump resistor (For driving pump in emergency) W-5 V14 DT 2 Solenoid valve for bottom dump close L2
K30 DT 3 CAN terminal resistance K-9 V21 D 2 PC-EPC solenoid valve L-6
K31 DT 3 CAN terminal resistance N-4 V22 D 2 LS-EPC solenoid valve L-6
M07 M 3 Light switch P-8 V30 X 2 ATT flow adjustment EPC solenoid valve P-1
M09 M 1 Working lamp (Right front) E-9 W03 M 2 Rear limit switch (Window) AB-9
M13 M 2 Speaker (Right) AC-9 W04 M 6 Wiper motor Y-5
M19 YAZAKI 2 Cigarette lighter N-3 X05 M 4 Swing lock switch Q-8
PC400/450(LC)-7 90-19
(9)
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) PC400, 450-7 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE) PC400, 450-7
Connector No. of Connector No. of

Type Name of device Address Type Name of device Address
No. pins No. pins
A01 X 4 Intermediate connector T-1 M19 YAZAKI 2 Cigarette lighter N-3
A02 X 4 Intermediate connector T-1 M21 PA 9 Radio U-2
A03 DT 12 Intermediate connector N-2 M22 Y090 2 Horn switch O-7
A04 SWP 6 Intermediate connector O-1 M23 Y090 2 One-touch power maximizing switch T-1
A05 SWP 14 Intermediate connector T-1 M26 S 12 Intermediate connector W-4
A06 SWP 14 Intermediate connector O-1 M27 YAZAKI 18 Air conditioner unit W-4
A07 SWP 16 Intermediate connector S-1 M29 040 20 Air conditioner control panel U-2
A09 SWP 8 Intermediate connector N-2 M30 040 16 Air conditioner control panel U-2
A10 Terminal 1 Revolving frame grounding H-2 M31 M 2 Optional power supply (2) W-7
A11 Terminal 1 Revolving frame grounding I-2 M32 M 2 Optional power supply (1) W-6
A12 Terminal 1 Revolving frame grounding I-2 M33 M 2 Optional power supply (3) V-9
A13 Terminal 1 Revolving frame grounding I-2 M33 SUMITOMO 4 Air conditioner unit W-4
A14 Terminal 1 Revolving frame grounding F-1 M34 X 1 Air conditioner compressor electromagnetic clutch I-9
A15 Terminal 1 Revolving frame grounding J-3 M37 Terminal 1 Horn switch (High tone) H-1
A16 Terminal 1 Revolving frame grounding J-3 M38 Terminal 1 Horn switch (Low tone) G-1
A20 Terminal 1 Battery relay (Terminal E) D-1 M38 M 2 Machine push-up switch Q-8
A21 Terminal 1 Battery relay (Terminal BR) D-2 M40 M 2 Working lamp Z-8
A22 Terminal 1 Battery relay (Terminal N) F-2 M41 M 2 Working lamp (Additional) Y-7
A23 Terminal 1 Battery relay (Terminal B) F-2 M42 M 1 Intermediate connector H-9
A31 D 2 Air cleaner clogging sensor H-9 M43 M 1 Working lamp (Rear) J-9
A33 X 2 Radiator water level sensor H-9 M45 D 12 Intermediate connector W-7
A34 L 2 Fusible link (65 A) D-2 M46 X 4 RS232C junction connector V-9
A35 M 2 Fusible link (30 A) G-9 M71 M 2 Room lamp AA-8
A40 Terminal 1 Horn (Low tone) G-9 M72 M 4 DC/DC converter U-2
A41 Terminal 1 Horn (High tone) G-9 M73 M 2 Speaker (Left) AD-8
A42 M 1 Intermediate connector H-9 M79 M 2 12-V accessory outlet V-9
A43 D 2 Travel alarm J-3 NE YAZAKI 2 Engine Ne sensor AJ-5
A44 M 1 Right headlamp D-5 OL DT 2 Engine oil level sensor AJ-3
A50 KES0 2 Windshield washer motor (Tank) L-5 P01 070 12 Monitor panel N-6
A51 D 3 F pump oil pressure sensor L-8 P02 040 20 Monitor panel N-5
A52 D 3 R pump oil pressure sensor L-7 P03 M 2 Buzzer cancel switch Q-8
A60 X 1 Fuel level sensor G-9 P05 M 2 Rotary lamp switch U-2
A61 D 2 Hydraulic oil temperature sensor L-5 P15 Y050 2 Air conditioner daylight sensor N-5
A70 D 3 Boom cylinder bottom pressure sensor for overload alarm H-1 P70 040 16 Monitor panel N-5
A73 D 2 Fuel priming pump G-9 PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2
A80 DT 8 Intermediate connector S-1 PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2
AL/B Terminal 1 Alternator B terminal AE-6 PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2
AL/E Terminal 1 Alternator E terminal AE-6 PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1
AL/R Terminal 1 Alternator R terminal AE-6 PFUEL AMP 3 Common rail pressure sensor AJ-4
C01 DRC 24 Pump controller U-9 PIM SUMITOMO 3 Boost pressure sensor AJ-8
C02 DRC 40 Pump controller U-9 R10 R 5 Light relay P-7
C03 DRC 40 Pump controller W-9 R11 R 5 Starting motor cutout relay (PPC lock) P-8
C09 S 8 Model selection connector (Pump controller) W-9 R13 R 5 Starting motor cutout relay (Personal code) Q-8
CB1 DRC 24 Pump controller I-9 R20 R 5 ATT circuit selector relay W-7
CB2 DRC 40 Pump controller I-9 R22 R 5 Power supply relay for engine controller W-6
CB3 DRC 40 Pump controller J-9 R30 R 5 Air conditioner blower relay W-4
CB5 DT 8 Model selection connector (Engine controller) J-9 R31 R 5 Air conditioner compressor relay W-3
CN1 DT 2 No. 1 fuel injector AI-2 S01 D 4 Bucket CURL pressure sensor K-3
CN2 DT 2 No. 2 fuel injector AI-3 S02 X 2 Boom LOWER oil pressure switch L-2
CN3 DT 2 No. 3 fuel injector AJ-3 S03 X 2 Swing RIGHT oil pressure switch L-2
CN4 DT 2 No. 4 fuel injector AJ-5 S04 D 3 Arm IN pressure switch K-3
CN5 DT 2 No. 5 fuel injector AJ-6 S05 X 2 Bucket DUMP oil pressure switch L-2
CN6 DT 2 No. 6 fuel injector AJ-6 S06 X 2 Boom RAISE oil pressure switch L-2
D01 SWP 8 Concentrated diode W-7 S07 X 2 Swing LEFT oil pressure switch L-2
D02 SWP 8 Concentrated diode W-5 S08 X 2 Arm DUMP oil pressure switch L-1
E06 M 3 Fuel control dial P-7 S09 X 2 Service oil pressure switch (Intermediate connector) L-1
ENE DT 2 Engine speed sensor AJ-5 S10 X 2 Service front oil pressure switch K-1
ER02 HD30 31 Intermediate connector AF-8 S11 X 2 Service rear oil pressure switch L-1
ER03 HD30 31 Intermediate connector AF-8 S14 M 3 Safety lock lever switch S-1
F02 M 2 Rotary lamp AA-9 S21 Terminal 6 Emergency pump drive switch R-9
FB1 — — Fuse box V-2 S22 Terminal 6 Swing holding brake release switch R-8
G YAZAKI 2 Engine G sensor AH-2 S25 S090 16 Intermediate connector R-9
GND DT 2 Joint connector (with diode) AJ-6 S30 X 2 Travel oil pressure switch P-1
GND2 Terminal 1 Engine grounding AJ-5 S31 X 2 Travel steering oil pressure switch P-1
GND3 Terminal 1 Engine grounding AE-7 ST DT 2 Starting motor AF-7
H08 M 8 Intermediate connector W-6 ST/B Terminal 1 Starting motor B terminal AF-7
H09 S 8 Intermediate connector W-6 T05 Terminal 1 Floor frame grounding V-3
H10 S 16 Intermediate connector T-9 T06 Terminal 1 Radio body grounding S-9
H11 S 16 Intermediate connector S-9 T06A M 1 Intermediate connector T-2
H12 S 12 Intermediate connector S-9 T11 Terminal 1 Cab grounding
H15 S090 20 Intermediate connector O-7 THL DT 3 Spill fuel temperature sensor AJ-4
HT/B Terminal 1 Heater relay B terminal AH-9 TWH DT 2 Engine water temperature sensor (High temperature) AE-7
HT/S Terminal 1 Heater relay S terminal AJ-7 TWL DT 3 Engine water temperature sensor (Low temperature) AG-8
J01 J 20 Junction connector (Black) T-9 V01 DT 2 PPC oil pressure lock solenoid valve J-3
J02 J 20 Junction connector (Black) T-9 V02 DT 2 Travel junction solenoid valve J-2
J03 J 20 Junction connector (Green) U-9 V03 D 2 Merge-divider solenoid valve J-2
J04 J 20 Junction connector (Green) V-3 V04 D 2 Travel speed solenoid valve J-2
J05 J 20 Junction connector (Pink) V-3 V05 D 2 Swing holding brake solenoid valve J-2
J06 J 20 Junction connector (Orange) W-3 V06 D 2 Machine push-up solenoid valve J-2
J07 J 20 Junction connector (Orange) W-5 V08 D 2 2nd-stage relief solenoid valve J-1
J08 J 20 Junction connector (Pink) W-5 V12 D 2 ATT return selector solenoid valve J-1
K19 M 2 Pump resistor (For driving pump in emergency) W-5 V21 D 2 PC-EPC solenoid valve L-6
K30 DT 3 CAN terminal resistance K-9 V22 D 2 LS-EPC solenoid valve L-6
K31 DT 3 CAN terminal resistance N-4 V30 X 2 ATT flow adjustment EPC solenoid valve P-1
M07 M 3 Light switch P-8 W03 M 2 Rear limit switch (Window) AB-9
M09 M 1 Working lamp (Right front) E-9 W04 M 6 Wiper motor Y-5
M13 M 2 Speaker (Right) AC-9 X05 M 4 Swing lock switch Q-8
PC400/450(LC)-7 90-21
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SEBM033009

MACHINE MODEL SERIAL No.

• PC400, 400LC, PC450, 450LC-7 mount the SAA6D125E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ......................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

q 00-1 (9) 01-1 (8) 10-10 10-41 10-71 (8)

Time of Time of Time of Time of Time of

10-71-29 (8) 10-87 10-145 (1) 10-186 Q 20-17 (9)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

30-30 (2) 30-70 (2) 30-110 (2)

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES