PC 400 - 450 LC-8

UEN02223-00
HYDRAULIC
EXCAVATOR
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8
PC450-8
PC450LC-8
SERIAL NUMBERS K50001 and up
PC450LCD-8
PC450LCHD-8
UEN02225-00
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8
Machine model Serial number

PC450-8 K50001 and up
PC450LC-8 K50001 and up
PC450LCD-8 K50001 and up
PC450LCHD-8 K50001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
PC450/LC/LCD/LCHD-8 1
UEN02225-00 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs UEN02223-00
00 Index and foreword

Index UEN02225-00
Foreword and general information UEN02226-00
01 Specification
Specification and technical data UEN02228-00
10 Structure, function and maintenance standard

Engine and cooling system UEN02230-00
Power train UEN02231-00
Undercarriage and frame UEN02232-00
Hydraulic system, Part 1 UEN02233-00
Work equipment UEN02236-00
Cab and its attachments UEN02237-00
Electrical system UEN02238-00
20 Standard value table

Standard service value table UEN02643-00
30 Testing and adjusting

Testing and adjusting, part 1 UEN02644-00
Testing and adjusting, Part 2 UEN02645-00
40 Troubleshooting
Failure code table and fuse locations UEN02646-00
General information on troubleshooting UEN02647-00
Troubleshooting by failure code (Display of code), Part 1 UEN02648-00
Troubleshooting of electrical system (E-mode) UEN02651-00
Troubleshooting of hydraulic and mechanical system (H-mode) UEN02652-00
2 PC450/LC/LCHD-8
00 Index and foreword UEN02225-00
Troubleshooting of engine (S-mode) UEN02653-00
50 Disassembly and assembly

General information on disassembly and assembly UEN02654-00
Hydraulic system UEN02658-00
90 Diagrams and drawings

Hydraulic diagrams and drawings UEN02244-00
Electrical diagrams and drawings UEN02245-00
PC450/LC/LCHD-8 3
Table of contents 1
00 Index and foreword
Index UEN02225-00
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information UEN02226-00

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data UEN02228-00
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 6
Table of fuel, coolant and lubricants ............................................................................................ 8
10 Structure, function and maintenance standard

Engine related parts .................................................................................................................... 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train .................................................................................................................................. 2
Final drive.................................................................................................................................... 4
Sprocket ...................................................................................................................................... 6
Swing machinery ......................................................................................................................... 8
Swing circle ................................................................................................................................. 10
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................. 4
Carrier roller ................................................................................................................................ 6
Track roller................................................................................................................................... 7
Track shoe................................................................................................................................... 8
Hydraulic equipment layout drawing ........................................................................................... 2
Hydraulic tank and filter............................................................................................................... 4
Hydraulic pump ........................................................................................................................... 6
Control valve ............................................................................................................................... 2
CLSS ........................................................................................................................................... 14
Functions and operation by valve................................................................................................ 18
Attachment circuit selector valve................................................................................................. 58
Holding valve............................................................................................................................... 60
4 PC450/LC/LCHD-8

Valve control................................................................................................................................ 2
Solenoid valve............................................................................................................................. 20
PPC accumulator ........................................................................................................................ 22
Return oil filter ............................................................................................................................. 23
Center swivel joint ....................................................................................................................... 24
Travel motor ................................................................................................................................ 25
Swing motor ................................................................................................................................ 37
Hydraulic cylinder........................................................................................................................ 46
Work equipment .......................................................................................................................... 2
Dimensions of components ......................................................................................................... 4
Air conditioner piping................................................................................................................... 2
Engine control ............................................................................................................................. 2
Electronic control system ............................................................................................................ 13
Monitor system............................................................................................................................ 38
Idle stop guidance function ......................................................................................................... 62
User code/failure code display function ...................................................................................... 64
Sensor......................................................................................................................................... 65
KOMTRAX terminal system ........................................................................................................ 68
20 Standard value table

Standard service value table UEN02643-00
Standard value table for engine related parts.............................................................................. 2
Standard value table for chassis related parts ............................................................................ 3
30 Testing and adjusting

Testing and adjusting, part 1 UEN02644-00
Tools for testing, adjusting and troubleshooting .......................................................................... 3
Measuring engine speed............................................................................................................. 7
Measuring air boost pressure...................................................................................................... 8
Measuring exhaust temperature ................................................................................................. 9
Measuring exhaust gas color ...................................................................................................... 10
Adjusting valve clearance ........................................................................................................... 11
Measuring compression pressure ............................................................................................... 13
Measuring blow-by pressure ....................................................................................................... 15
Measuring engine oil pressure .................................................................................................... 16
Handling fuel system parts .......................................................................................................... 17
Releasing residual pressure from fuel system ............................................................................ 17
Measuring fuel pressure.............................................................................................................. 18
Handling during cylinder cut-out operation.................................................................................. 19
Handling during no injection cranking operation ......................................................................... 19
Measuring fuel return rate and leakage ...................................................................................... 20
Bleeding air from fuel circuit........................................................................................................ 23
Checking fuel circuit for leakage ................................................................................................. 24
Checking and adjusting fan belt and alternator belt .................................................................... 25
Checking and adjusting air conditioner compressor belt tension ................................................ 26
Measuring swing circle bearing clearance .................................................................................. 27
Checking and adjusting track shoe tension................................................................................. 28
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................. 29
Measuring control circuit basic pressure..................................................................................... 33
Checking and adjusting pump PC control circuit oil pressure ..................................................... 34
Checking and adjusting pump LS control circuit oil pressure...................................................... 37
Measuring solenoid valve output pressure.................................................................................. 42
Measuring PPC valve output pressure........................................................................................ 45
PC450/LC/LCHD-8 5
Adjusting play of work equipment and swing PPC valves........................................................... 46

Inspecting locations of hydraulic drift of work equipment ............................................................ 47
Releasing residual pressure from hydraulic circuit...................................................................... 49
Measuring oil leakage amount .................................................................................................... 50
Bleeding air from various parts.................................................................................................... 53
Special functions of machine monitor.......................................................................................... 2
Handling voltage circuit of engine controller................................................................................ 2
Preparation work for troubleshooting of electrical system ........................................................... 3
Procedure for testing diodes ....................................................................................................... 8
Pm Clinic service......................................................................................................................... 9
Undercarriage troubleshooting report.......................................................................................... 15
40 Troubleshooting
Failure code table and fuse locations UEN02646-00
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 5
General information on troubleshooting UEN02647-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and troubleshooting steps ..................................................................................... 5
Information in troubleshooting table ............................................................................................ 6
Wiring table for connector pin numbers....................................................................................... 11
T-adapter box and T-adapter table .............................................................................................. 44
Failure code [A000N1] Eng. Hi Out of Std................................................................................... 3
Failure code [AA10NX] Air cleaner Clogging .............................................................................. 4
Failure code [AB00KE] Charge Voltage Low............................................................................... 6
Failure code [B@BAZG] Eng Oil Press. Low .............................................................................. 8
Failure code [B@BAZK] Eng Oil Level Low ................................................................................ 10
Failure code [B@BCNS] Eng. Water Overheat ........................................................................... 12
Failure code [B@BCZK] Eng Water Level Low ........................................................................... 14
Failure code [B@HANS] Hydr Oil Overheat................................................................................ 16
Failure code [CA111] EMC Critical Internal Failure ..................................................................... 17
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................ 17
Failure code [CA122] Chg Air Press Sensor High Error.............................................................. 18
Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 20
Failure code [CA131] Throttle Sensor High Error........................................................................ 22
Failure code [CA132] Throttle Sensor Low Error ........................................................................ 24
Failure code [CA135] Eng Oil Press Sensor High Error.............................................................. 26
Failure code [CA141] Eng Oil Press Sensor Low Error............................................................... 28
Failure code [CA144] Coolant Temp Sens High Error................................................................. 30
Failure code [CA145] Coolant Temp Sens Low Error.................................................................. 32
Failure code [CA153] Chg Air Temp Sensor High Error .............................................................. 34
Failure code [CA154] Chg Air Temp Sensor Low Error............................................................... 36
Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 38
Failure code [CA221] Ambient Press Sens High Error................................................................ 40
Failure code [CA222] Ambient Press Sens Low Error ................................................................ 42
Failure code [CA227] Sens Supply 2 Volt High Error .................................................................. 44
Failure code [CA234] Eng Overspeed......................................................................................... 45
Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................. 46
Failure code [CA263] Fuel Temp Sensor High Error ................................................................... 48
Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 50
Failure code [CA271] IMV/PCV1 Short Error .............................................................................. 51
Failure code [CA272] IMV/PCV1 Open Error .............................................................................. 52
6 PC450/LC/LCHD-8
Failure code [CA273] PCV2 Short Error ..................................................................................... 54

Failure code [CA274] PCV2 Open Error ..................................................................................... 55
Failure code [CA322] Inj #1 Open/Short Error ............................................................................ 56
Failure code [CA342] Calibration Code Incompatibility ............................................................... 3
Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error.................................................................. 8
Failure code [CA441] Battery Voltage Low Error ........................................................................ 10
Failure code [CA442] Battery Voltage High Error........................................................................ 12
Failure code [CA449] Rail Press Very High Error ....................................................................... 14
Failure code [CA451] Rail Press Sensor High Error ................................................................... 18
Failure code [CA452] Rail Press Sensor Low Error .................................................................... 20
Failure code [CA553] Rail Press High Error................................................................................ 22
Failure code [CA554] Rail Press Sensor In Range Error ............................................................ 23
Failure code [CA559] Rail Press Low Error ................................................................................ 24
Failure code [CA689] Eng Ne Speed Sensor Error..................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 28
Failure code [CA757] All Persistent Data Lost Error ................................................................... 30
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 32
Failure code [CA1228] EGR valve servo error 1......................................................................... 34
Failure code [CA1625] EGR valve servo error 2......................................................................... 35
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 36
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 38
Failure code [CA2186] Throt Sens Sup Volt Low Error............................................................... 39
Failure code [CA2249] Rail Press Very Low Error ...................................................................... 40
Failure code [CA2271] EGR valve lift sensor high error ............................................................. 42
Failure code [CA2272] EGR valve lift sensor low error ............................................................... 44
Failure code [CA2351] EGR valve solenoid operation short circuit ............................................ 46
Failure code [CA2352] EGR valve solenoid operation disconnect.............................................. 48
Failure code [CA2555] Grid Htr Relay Volt High Error ................................................................ 50
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................. 52
Failure code [D110KB] Battery Relay Drive S/C ......................................................................... 54
Failure code [DA25KP] 5V sensor power supply output 1 abnormality....................................... 56
Failure code [DA2RMC] Pump Comm. Abnormality ................................................................... 60
Failure code [DA2SKQ] Model Selection Abnormality ................................................................ 62
Failure code [DA2RMC] CAN discon (Pump con detected) ........................................................ 4
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...................................................... 6
Failure code [DHPBMA] R Pump Press Sensor Abnormality ..................................................... 8
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality .......................................................... 10
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ........................................ 12
Failure code [DW43KA] Travel Speed Sol. Disc. ........................................................................ 14
Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................... 16
Failure code [DW45KA] Swing Brake Sol. Disc. ......................................................................... 18
Failure code [DW45KB] Swing Brake Sol. S/C ........................................................................... 22
Failure code [DW91KA] Travel Junction Sol. Disc. ..................................................................... 24
Failure code [DW91KB] Travel Junction Sol. S/C ....................................................................... 26
Failure code [DWJ0KA] Merge-divider Sol. Disc......................................................................... 28
Failure code [DWJ0KB] Merge-divider Sol. S/C.......................................................................... 30
Failure code [DWK0KA] 2-stage Relief Sol. Disc. ....................................................................... 32
Failure code [DWK0KB] 2-stage Relief Sol. S/C ......................................................................... 34
Failure code [DXA0KA] PC-EPC Sol. Disc. ................................................................................ 36
PC450/LC/LCHD-8 7
Failure code [DXA0KB] PC-EPC Sol. S/C................................................................................... 38

Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................. 40
Failure code [DXE0KB] LS-EPC Sol. S/C ................................................................................... 42
Failure code [DXE4KA] Service Current EPC Disc. .................................................................... 44
Failure code [DXE4KB] Service Current EPC S/C ...................................................................... 45
Failure code [DY20KA] Wiper Working Abnormality ................................................................... 46
Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 48
Failure code [DY2CKB] Washer Drive Short ............................................................................... 50
Failure code [DY2DKB] Wiper Drive (For) Short ......................................................................... 52
Failure code [DY2EKB] Wiper Drive (Rev) Short ........................................................................ 54
Troubleshooting of electrical system (E-mode) UEN02651-00
Before carrying out troubleshooting of electrical system............................................................. 4
Information contained in troubleshooting table............................................................................ 6
E-1 Engine does not start............................................................................................................ 7
E-2 Auto-decelerator does not operate ....................................................................................... 10
E-3 Automatic warming-up system does not operate.................................................................. 12
E-4 Preheater does not operate .................................................................................................. 14
E-5 All work equipment, swing, and travel mechanism do not move .......................................... 16
E-6 Power maximizing function does not operate ....................................................................... 18
E-7 Machine monitor does not display at all................................................................................ 20
E-8 Machine monitor does not display some items..................................................................... 22
E-9 Contents of display by machine monitor are different from applicable machine................... 22
E-10 Fuel level monitor was lighted in red while engine running ................................................ 23
E-11 Engine coolant temperature gauge does not indicate normally .......................................... 24
E-12 Hydraulic oil temperature gauge does not indicate normally .............................................. 26
E-13 Fuel level gauge does not indicate normally....................................................................... 27
E-14 Swing lock monitor does not indicate normally................................................................... 28
E-15 When monitor switch is operated, monitor displays nothing............................................... 30
E-16 Windshield wiper and window washer do not operate........................................................ 32
E-17 Machine push-up function does not operate normally ........................................................ 36
E-18 Monitoring function fails to display “boom raise” normally .................................................. 38
E-19 Monitoring function fails to display “boom lower” normally ................................................. 40
E-20 Monitoring function fails to display “arm IN” normally ......................................................... 42
E-21 Monitoring function fails to display “arm OUT” normally ..................................................... 44
E-22 Monitoring function fails to display “bucket CURL” normally .............................................. 46
E-23 Monitoring function fails to display “bucket DUMP” normally.............................................. 48
E-24 Monitoring function fails to display “swing” normally........................................................... 50
E-25 Monitoring function fails to display “travel” normally ........................................................... 52
E-26 Monitoring function fails to display “travel differential pressure” normally .......................... 54
E-27 Monitoring function fails to display “service” normally ........................................................ 56
E-28 KOMTRAX system does not operate normally ................................................................... 58
E-29 Air conditioner does not operate......................................................................................... 60
E-30 Travel alarm does not sound or does not stop sounding .................................................... 62
E-31 Horn does not sound .......................................................................................................... 64
Troubleshooting of hydraulic and mechanical system (H-mode) UEN02652-00
System chart for hydraulic and mechanical system .................................................................... 4
Information contained in troubleshooting table............................................................................ 6
H-1 All work equipment lack power, or travel and swing speeds are slow .................................. 8
H-2 Engine speed sharply drops or engine stalls ........................................................................ 10
H-3 No work equipment, swing or travel move............................................................................ 11
H-4 Abnormal noise is heard from around hydraulic pump ......................................................... 11
H-5 Auto-decelerator does not work............................................................................................ 12
H-6 Fine control mode does not function or responds slow ........................................................ 12
H-7 Boom moves slowly or lacks power...................................................................................... 13
H-8 Arm moves slowly or lacks power ........................................................................................ 14
H-9 Bucket moves slowly or lacks power .................................................................................... 15
H-10 Work equipment does not move in its single operation ...................................................... 15
H-11 Work equipment has a bit too fast hydraulic drift ................................................................ 16
8 PC450/LC/LCHD-8
H-12 Work equipment has big time lag ....................................................................................... 18

H-13 Other work equipment moves when relieving single circuit................................................ 18
H-14 Power max. switch does not operate ................................................................................. 18
H-15 Machine push-up function does not operate. ..................................................................... 19
H-16 In compound operation of work equipment, speed of part loaded more is low .................. 20
H-17 When machine swings and raises boom simultaneously, boom rising speed is low .......... 20
H-18 When machine swings and travels simultaneously, travel speed lowers largely................ 20
H-19 Machine deviates during travel........................................................................................... 21
H-20 Travel speed is low............................................................................................................. 22
H-21 Machine is not steered well or steering power is low ......................................................... 23
H-22 Travel speed does not change or travel speed is low or high ............................................ 24
H-23 Travel system does not move (only one side) .................................................................... 25
H-24 Upper structure does not swing.......................................................................................... 26
H-25 Swing acceleration or swing speed is low .......................................................................... 28
H-26 Upper structure overruns remarkably when it stops swinging ............................................ 30
H-27 Large shock is made when upper structure stops swinging ............................................... 31
H-28 Large sound is made when upper structure stops swinging. ............................................. 31
H-29 Hydraulic drift of swing is large........................................................................................... 32
H-30 Attachment circuit is not changed ...................................................................................... 33
H-31 Oil flow in attachment circuit cannot be controlled ............................................................. 33
Troubleshooting of engine (S-mode) UEN02653-00
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 8
S-3 Engine does not pick up smoothly........................................................................................ 12
S-4 Engine stops during operations ............................................................................................ 13
S-5 Engine does not rotate smoothly .......................................................................................... 14
S-6 Engine lacks output (or lacks power).................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 17
S-9 Oil becomes contaminated quickly ....................................................................................... 18
S-10 Fuel consumption is excessive........................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 20
S-12 Oil pressure drops .............................................................................................................. 21
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 22
S-14 Coolant temperature becomes too high (overheating) ....................................................... 24
S-15 Abnormal noise is made ..................................................................................................... 25
S-16 Vibration is excessive ......................................................................................................... 26
50 Disassembly and assembly

General information on disassembly and assembly UEN02654-00
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tools list........................................................................................................................... 7
Sketches of special tools............................................................................................................. 11
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 6
Removal and installation of engine front seal ............................................................................. 12
Removal and installation of engine rear seal .............................................................................. 13
Removal and installation of cylinder head assembly .................................................................. 16
Removal and installation of radiator assembly............................................................................ 25
Removal and installation of hydraulic oil cooler assembly .......................................................... 27
Removal and installation of aftercooler assembly ....................................................................... 29
Removal and installation of engine and hydraulic oil pump assembly ........................................ 30
Removal and installation of final drive assembly ........................................................................ 2
PC450/LC/LCHD-8 9
Disassembly and assembly of final drive assembly .................................................................... 3

Removal and installation of swing motor and swing machinery assembly .................................. 11
Disassembly and assembly of swing motor and swing machinery assembly ............................. 12
Removal and installation of swing circle assembly ..................................................................... 19
Disassembly and assembly of carrier roller assembly ................................................................ 2
Disassembly and assembly of track roller assembly................................................................... 4
Disassembly and assembly of idler assembly............................................................................. 5
Disassembly and assembly of recoil spring assembly ................................................................ 8
Removal and installation of sprocket........................................................................................... 10
Expansion and installation of track shoe assembly ..................................................................... 11
Removal and installation of revolving frame assembly ............................................................... 13
Removal and installation of counterweight assembly.................................................................. 16
Hydraulic system UEN02658-00
Removal and installation of centre swivel joint assembly............................................................ 2
Disassembly and assembly of centre swivel joint assembly ....................................................... 4
Removal and installation of hydraulic tank assembly .................................................................. 5
Removal and installation of control valve assembly.................................................................... 7
Disassembly and assembly of control valve assembly ............................................................... 10
Removal and installation of hydraulic pump assembly................................................................ 14
Removal and installation of oil seal in hydraulic pump input shaft .............................................. 17
Disassembly and assembly of work equipment PPC valve assembly ........................................ 18
Disassembly and assembly of travel PPC valve assembly ......................................................... 19
Disassembly and assembly of hydraulic cylinder assembly........................................................ 20
Removal and installation of work equipment assembly............................................................... 2
Removal and installation of operator cab assembly.................................................................... 2
Removal and installation of operator cab glass (stuck glass) ..................................................... 5
Removal and installation of front window assembly.................................................................... 15
Removal and installation of floor frame assembly ....................................................................... 22
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of KOMTRAX communication modem assembly ................................ 5
Removal and installation of monitor assembly ............................................................................ 6
Removal and installation of pump controller assembly ............................................................... 8
Removal and installation of engine controller.............................................................................. 10
90 Diagrams and drawings

Hydraulic diagrams and drawings UEN02244-00
Hydraulic circuit diagram ............................................................................................................. 3
Electrical diagrams and drawings UEN02245-00
Electrical circuit diagram ............................................................................................................. 3
10 PC450/LC/LCHD-8
PC450/LC/LCHD-8 11
UEN02225-00
PC450/LC/LCD/LCHD-8 Hydraulic excavator

Form No. UEN02225-00
© 2007 KOMATSU
All Rights Reserved
Printed in Belgium 10-07 (01)
12
UEN02226-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
PC450PCD-8 K50001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 PC450/LC/LCD/LCHD-8
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pick-up plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified tor-
work on the oil or water circuits. ques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its centre of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowa-
ble load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

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

installation in each section of "Disassembly
and assembly".
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

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

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

a Caution
standards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

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

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

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

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

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
Handling electric equipment and hydraulic component 1

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

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

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

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

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-
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 connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
4) Drying wiring harness

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

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
Points to remember when handling hydraulic equipment

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

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

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

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

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

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

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

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

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

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

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

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pull-out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and colour of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates colour of wire by colour code.
Colour codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-volt- Conduc- Annealed copper for elec-
General wiring
age wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resist- Conduc- Annealed copper for elec-
General wiring in extremely
ant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant cross linked
Insulator perature place
automobile polyethylene
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
3. Colour codes table
(Table 3)
Colour Code Colour of wire Colour Code Colour of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a colour code consisting of 2 colours, the first colour is the colour of the background
and the second colour is the colour of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and colour codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

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

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

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
4) Checking muffler and exhaust pipe for damage and looseness

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

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

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
2. Table of tightening torques for split flange bolts

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

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

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

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimetres to inches
1. Convert 55 mm into inches.

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

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimetres to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Millimetres 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
Litres to U.S. Gallons

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

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

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
UEN02226-00
PC450/LC/LCHD-8 Hydraulic excavator

© 2007 KOMATSU
All Rights Reserved
42
UEN02228-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
01 Specification 1
Specification and technical data
Specification dimension drawings ................................................................................................................... 2
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 6
Table of fuel, coolant and lubricants................................................................................................................ 8
UEN02228-00 01 Specification
Specification dimension drawings 1

Dimensions 1
1
7.1M Boom, 3.4M Arm 6.7M Boom, 3.4M Arm
Item Unit PC450LC-8
PC450-8 PC450LCHD-8
PC450LCD-8
A Overall length mm 12,040 12,040 11,570
B Overall height mm 3,660 3,660 3,660
C Overall width mm 3,490 3,490 3,490
D Track shoe width mm 600 600 600
E Height of machine cab mm 3250 3250 3250
F Tail swing radius mm 3,645 3,645 3,645
G Track overall length mm 5,055 5,355 5,376
H Length of track on ground mm 4,020 4,350 4,350
J Max. ground clearance mm 685 685 685
01 Specification UEN02228-00
Working ranges 1
7.1M Boom, 3.4M Arm 6.7M Boom, 3.4M Arm

Working range Unit PC450LC-8
PC450-8 PC450LCHD-8
PC450LCD-8
A Max. digging reach mm 12,005 12,005 11,690
B Max. digging depth mm 7,790 7,790 7,385
C Max. digging height mm 10,925 10,925 11,045
D Max. vertical wall depth mm 6,600 6,600 6,585
E Max. dumping height mm 7,625 7,625 7,665
F Min. dumping height mm — — —
G Max. reach at ground level mm 11,800 11,800 11,477
Specifications 1
PC450-8, PC450LC-8
PC450LC-8
Machine model PC450-8 PC450LCHD-8
PC450LCD-8
Serial Number K45001 and up
Bucket capacity kg 2200 2200 2300
Operating weight kg 43,500 45,000 46,500
Max. digging depth mm 7,790 7,790 7,385
Working ranges
Max. vertical wall depth mm 6,600 6,600 6,585

Max. digging reach mm 12,005 12,005 11,690
Max. reach at ground level mm 11,800 11,800 11,477
Max. digging height mm 10,925 10,925 11,045
Max. dumping height mm 7,625 7,625 7,665
Performance
Max. digging force kN {kg} 256.0 {26,100} 256.0 {26,100} 256.0 {26,100}
(using power max. function) (274.6 {28,000}) (274.6 {28,000}) (274.6 {28,000})
Swing speed rpm 9.1 9.1 9.1
Swing max. slope angle deg. 17 17 17
Travel speed km/h Lo: 3.0, Mi: 4.4, Hi: Lo: 3.0, Mi: 4.4, Hi: Lo: 3.0, Mi: 4.4,
5.5 5.5 Hi: 5.5
Gradeability deg. 35 35 35
Ground pressure kPa {kg/cm2} 81.8 {0.84} 82.8 {0.85} 79.9 {0.82}
Overall length (for transport) mm 12,040 12,040 11,570

Overall width mm 3,490 3,490 3,490
Overall width of track mm 2,990 2,990 2,990
Overall width of track when mm 3,490 3,490 3,490
extended
Overall height (for transport) mm 3,660 3,660 3,660
Overall height to top of machine mm 3,265 3,265 3,265
Dimensions
Ground clearance of upper structure mm 1,320 1,320 1,320

Min. ground clearance mm 685 685 685
Tail swing radius mm 3,645 3,645 3,645
Min. swing radius of work equipment mm 4,805 4,805 4,395
Height of work equipment mm 9,230 9,230 9,025
at min. swing radius
Tumbler centre mm 4,020 4,350 4,350
Track gauge mm 2,890 2,890 2,890
Height of machine cab mm 3,250 3,250 3,250
Width of standard shoe mm 600 600 600
PC450-8, PC450LC-8
PC450LC-8
PC450LCD-8
Serial number K45001 and up
Model SAA6D125E-5
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
No. of cylinders – bore × stroke mm 6 – 125 × 150
Piston displacement l {cc} 11.045 {11,045}
Flywheel horsepower kW/rpm {HP/rpm} 257/1,900 {345/1,900}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 1,383/1,400 {141/1,400}

Max. speed at no load rpm 1,930
Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HPh} 203 {147}
Starting motor 24V, 11 kW
Alternator 24 V, 50 A
Battery 12V, 140 Ah × 2
Radiator core type Alminum wave type, 4 rows
Carrier roller 2 on each side
Undercarriage
Track roller 7 on each side 8 on each side 8 on each side

Assembly-type Assembly-type tri- Assembly-type
Track shoe triple grouser, 46 ple grouser, 49 on double grouser, 49
on each side each side on each side
Type × No. HPV190+190, ariable displacement, piston type × 2
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
KMV200ADT-2, Variable displacement, piston type

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

Swing motor
(with safety valve, holding brake, reverse rotation preventive
valve): × 1
Arm (*1),(*2)
Boom (*1) Arm (*1),(*2) Bucket
2.4M
Double-acting Double-act-
Hydraulic cylinder
Type Double-acting piston

piston ing piston
Inside diameter of cylinder mm 160 185 185 160
Outside diameter of piston rod mm 110 120 120 100
Stroke mm 1,570 1,820 1,590 1,270
Max. distance between pins mm 3,830 4,325 4,250 3,140
Min. distance between pins mm 2,260 2,505 2,660 1,870
Hydraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler CF40-1 (Air cooled)
*1: Cushion is provided on head side

*2: Cushion is provided on bottom side
Weight table 1
PC450-8, PC450LC-8
Unit: kg
PC450LC-8
(PC450LCD-8)
Engine assembly 1,660 1,660
• Engine 1,314 1,314
• Damper 14.7 14.7
• Hydraulic pump 210 210
Radiator oil cooler assembly 213 213
Hydraulic tank, filter assembly
198 198
(excluding hydraulic oil)
Fuel tank (excluding fuel) 251 251
3,402
Revolving frame 3,402
(3,673)
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
Track frame assembly 11,697 12,244 11,124
Track frame 6,766 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
Unit: kg
Machine model PC450-8 PC450LC-8 PC450LCHD-8
Track shoe assembly
Standard triple grouser shoe (600 mm) 4,470 4,760 —
Standard triple grouser shoe (700 mm) 4,890 5,210 —
Wide triple grouser shoe (800 mm) 5,320 5,670 —
Standard triple grouser shoe (900 mm) — 6,130 —
Standard double grouser shoe (600 mm) 5,520 5,880
Boom assembly 3,380 3,380 3,140
Arm assembly 1,622 1,622
Bucket assembly 1,941 1,941
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 510 510
Bucket cylinder assembly 297 297
Link assembly 258 258
92 + 20 × 2 + 73 +
Boom pin 92 + 20 × 2 + 73 + 27 + 54
27 + 54
Arm pin 17 + 23 17 + 23
Bucket pin 38 × 2 38 × 2
Link pin 34 × 2 34 × 2
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
Unit: l
PC450-8,450LC-8, PC450LCHD-8
Reservoir
Specified (l) Refill (l)
Engine oil pan 46 37
Swing machinery case 20 20
Final drive case (each side) 10.5 10.5
Damper case 1.07 —
Hydraulic system 472 248
Fuel tank 650 —
Cooling system 36 —
a For the HO46-HM, use the oil recommended by Komatsu.
UEN02228-00

© 2007 KOMATSU
All Rights Reserved
10
UEN02230-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine related parts ........................................................................................................................................ 2
Radiator, oil cooler and aftercooler ................................................................................................................. 3
UEN02230-00 10 Structure, function and maintenance standard
Engine related parts 1
1. Damper assembly Outline

2. Drive plate A wet type damper assembly is used.
3. Torsion spring Oil capacity: 1.07 l
4. Stopper pin
5. Friction plate
6. Muffler
7. Rear engine mount
8. Front engine mount
10 Structure, function and maintenance standard UEN02230-00
Radiator, oil cooler and aftercooler 1
1. Oil cooler 6. Net

2. Radiator 7. Shroud
3. Radiator cap 8. Radiator outlet hose
4. Radiator inlet hose 9. Aftercooler
5. Reservoir tank 10. Condenser
Specifications
Radiator: Aluminium wave type, 4 rows
Oil cooler: CF40-1
UEN02230-00

© 2007 KOMATSU
All Rights Reserved
4
UEN02231-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Power train
Power train...................................................................................................................................................... 2
Final drive ....................................................................................................................................................... 4
Sprocket .......................................................................................................................................................... 6
Swing machinery............................................................................................................................................. 8
Swing circle................................................................................................................................................... 10
Power train 1
1. Idler
2. Centre swivel joint
3. Control valve
4. Final drive
5. Travel motor (KMV200ADT-2)
6. Engine (SAA6D125E-5)
7. Hydraulic pump (HPV190+190)
8. Travel speed solenoid valve
9. Swing brake solenoid valve
10. Swing machinery
11. Swing motor (KMF230ABE-5)
12. Swing circle
Final drive 1
1. Level plug 8. Cover

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

16 carrier and motor 0.06 – 0.24 —
Replace
Backlash between No. 2 sun gear

18 gear and ring gear 0.17 – 0.60 1.20

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

Standard size Repair limit Rebuild or replace
21 Width of sprocket tooth
90 87
Sprocket 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip
355 343
Build-up welding
2 Thickness of tooth root 20.8 14.8
for rebuilding or
3 Width of tooth 90 87 replace
Repair limit: 6 (measure with the full-size drawing of sprocket tooth
4 Wear of tooth shape shape)
Full-size drawing of sprocket tooth shape
a The above drawing is reduced to 61%. Enlarge it to 164% to return it to the full scale and make a copy
on an OHP sheet.
Swing machinery 1
1. Swing pinion (No. of teeth: 13) 8. Swing motor

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


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


Backlash between coupling and

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

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

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

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

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

b. Outer race soft zone "S" position
Unit: mm
Axial clearance of bearing Standard clearance Repair limit
4 (when mounted on chassis) Replace
0.5 – 1.6 3.2
UEN02231-00

© 2007 KOMATSU
All Rights Reserved
12
UEN02232-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Undercarriage and frame
Track frame and recoil spring.......................................................................................................................... 2
Idler ................................................................................................................................................................. 4
Carrier roller .................................................................................................................................................... 6
Track roller ...................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
Track frame and recoil spring 1

a The following drawing indicates PC400LC-8 and PC450LC-8.
1. Idler q The dimensions and the number of track roll-

2. Track frame ers depend on the model, but the basic struc-
3. Carrier roller ture is not different.
4. Final drive q Number of track rollers
5. Track roller
6. Track shoe Model Q'ty (one side)
7. Centre guard PC450-8 7
8. Front guard PC450LC-8,
PC450LCD-8 8
PC450LCHD-8
Standard shoe
Models PC450LC-8, PC450LCD-8,
PC450-8
Item PC450LCHD-8
Shoe width 600 mm 600 mm
Link pitch 228 mm 228 mm
No. of shoes (one side) 46 (Pieces) 49 (Pieces)
Unit: mm
Standard size Tolerance Repair limit
Track +3
Vertical width of idler 148 —
9 guide frame –1
Idler
145 ±0.5 — Rebuild or replace
support
Track +4
302 —
Horizontal width of idler frame –1
10 guide Idler
297 — —
support
Free length × Installation Installation Installation
Free length
11 Recoil spring O.D. length load load Replace
239 kN
845.3 × 262 690 — —
{24,375 kg}
Idler 1
Unit: mm
1 Outside diameter of protrusion
704 —
2 Outside diameter of tread 660 648
3 Depth of tread 22 28 Rebuild or replace
4 Thickness of tread 21 15
5 Total width 202 —
6 Width of tread 48.5 54.5
Clearance between bushing and
7 support 0.46 – 0.86 —
(Sum of clearance at both sides)
Tolerance
Standard size Standard clearance
Clearance between shaft and Shaft Hole
8 bushing –0.120 +0.360 Replace bushing
95 0.340 – 0.567
–0.207 +0.220
Tolerance Standard
Standard size
Interference between idler and Shaft Hole interference
9 bushing
+0.087 –0.027
102.6 0.010 – 0.149
+0.037 –0.062
Carrier roller 1
Unit: mm
1 Outside diameter of flange
179 —
3 Width of tread 50.3 —
4 Thickness of tread 32 25
5 Width of flange 19 —
Standard Tolerance Standard Clearance
Clearance between shaft and bush- size Shaft Hole clearance limit Replace
6 ing –0.250 +0.074 0.250 –
54 —
–0.280 +0.040 0.354
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
7 bushing +0.117 +0.030 0.057 –
61 —
+0.087 +0.040 0.117
Standard clearance Clearance limit
8 Axial clearance of roller
0.5 – 0.7 —
Track roller 1
Unit: mm
1 Outside diameter of outer flange
240 —
Outside diameter of inner flange
2 (Double flange)
237 —

4 Thickness of tread 56.2 50.2 Build-up welding
5 Overall width 278 — for rebuilding or
replace
Single flange 54.6
6 Width of tread —
Double flange 51.6
Width of outer Single flange 34.4 —
7 flange
Double flange 34.4 —
Width of inner flange
8 (Double frame) 23.0 —
9 Axial play 0.4 – 1.0 —

Clearance between shaft and size Shaft Hole clearance limit
10 bushing –0.250 +0.174 0.279 –
80 —
–0.350 +0.029 0.524 Replace bushing
Standard Tolerance Standard Interference
Interference between roller and size Shaft Hole interference limit
11 bushing +0.087 +0.022 0.015 –
87.6 —
+0.037 –0.013 0.100
Track shoe 1
a P portion shows the link of bushing press fitting end.
Unit: mm
1 Link pitch
228.9 231.9 Reverse or
Standard size Reverse replace
2 Outside diameter of bushing
71.5 66.5
3 Thickness of bushing metal 11.9 6.9 Adjust or replace
4 Link height
129 119
Repair or replace
Thickness of link metal (bushing
5 press-fitting portion)
34.5 24.5
Unit: mm
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
Inside
9 width
106
Overall
10 Link width
51.6 Repair or replace
Tread
11 width
44.8
12 Protrusion of pin 4.4

13 Protrusion of regular bushing 5.25
14 Overall length of pin 252 Adjust or replace
15 Overall length of bushing 164.5
16 Thickness of spacer —
17 Bushing 118 – 304 kN {12 – 31 ton}
Regular
18 pin
176 – 451 kN {18 – 46 ton}
Press-fitting force —
19 Master
137 – 284 kN {14 – 29 ton}
(*) pin
Tightening torque
Retightening angle (deg.)
a. Regu- (Nm {kgm})
lar link 393±39
Triple grouser shoe 120±10
20 Shoe bolt {40±4} Retighten
Tightening torque Lower limit torque
b. Master Retightening angle (deg.)
(Nm {kgm}) (Nm {kgm})
link
— — —
Tolerance Standard
Standard size
Interference between bushing and Shaft Hole interference
21 link
+0.494 +0.074
71 0.380 – 0.494
+0.454 +0.074
Interference between regular pin +0.235 –0.218
22 and link 47
+0.085 –0.280
0.303 – 0.515
Tolerance
Clearance between regular pin and Shaft Hole
23 bushing +0.235 +0.915
47 0.180 – 0.830 Adjust or replace
+0.085 +0.415
Tolerance Standard interfer-
Standard size
24 Interference between master pin Shaft Hole ence
(*) and bushing +0.03 –0.218
47 0.218 – 0.310
+0.03 –0.280
Tolerance
25 Clearance between master pin and Shaft Hole
(*) bushing –0.2 +0.915
47 0.615 – 1.315
–0.4 +0.415
* Dry type track link
Triple grouser shoe
Unit: mm
1 Height
37 22
2 Thickness 13
3 33
Length of base
4 27 Build-up welding
for rebuilding or
5 25.5 replace
6 Length at tip 17.5
7 23.5
8 Thickness
50 35
UEN02232-00

© 2007 KOMATSU
All Rights Reserved
12
UEN02233-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
PC450LCHD-8 H50001 and up

Hydraulic system, Part 1
Hydraulic equipment layout drawing ............................................................................................................... 2
Hydraulic tank and filter .................................................................................................................................. 4
Hydraulic pump ............................................................................................................................................... 6
Hydraulic equipment layout

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

2. Breather Tank capacity: 335 l
3. Hydraulic tank Amount of oil inside tank: 248 l
4. Sight gauge
5. Strainer Pressure valve
6. Filter element Relief cracking pressure:
7. Strainer 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2}
8. Bypass valve Suction cracking pressure:
0 – 0.49 kPa {0 – 0.005 kg/cm2}
Bypass valve
Set pressure: 150 ± 30 kPa {1.5 ± 0.3 kg/cm2}
Hydraulic pump 1
Type: HPV160+160 (190)
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
EPC valve and variable volume valve.
BMP: Breather installation port

IM: PC mode selector current
ISIG: LS set pressure selector current
OCP: Oil level pick-up port
PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Drain plug
PD2R: Drain plug
PENF: Front control pressure pick-up port
PENR: Rear control pressure pick-up port
PEPC: EPC basic pressure port
PEPB: EPC basic pressure pick-up port
PFC: Front pump discharge pressure pick-up port
PLSCR: LS set selector pressure pick-up port
PLSF: Front load pressure input port
PLSFC: Front load pressure pick-up port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pick-up port
PM: PC mode selector pressure pick-up port
PRC: Rear pump discharge pressure pick-up port
PS: Pump suction port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. LS-EPC valve
6. PC-EPC valve
7. Variable volume valve
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
Function
q The pump converts the engine rotation trans-
mitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by q Piston (6) carries out relative movement in the
spline (14). axial direction inside each cylinder chamber of
q Shaft (1) is supported by front and rear bear- cylinder block (7).
ings (15). q Cylinder block (7) seals the pressurized oil to
q Tip of piston (6) is shaped as a concave ball valve plate (8) and carries out relative rotation.
and shoe (5) is caulked to it to form one unit. q This surface is designed so that the oil pres-
q Piston (6) and shoe (5) constitute the spherical sure balance is maintained at a suitable level.
bearing. q The oil inside each cylinder chamber of cylin-
q Rocker cam (4) has flat surface (A), and shoe der block (7) is suctioned and discharged
(5) is always pressed against this surface while through valve plate (8).
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
Operation of pump
q Cylinder block (7) rotates together with shaft q As centre line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between centre line (X) of rocker cam (4) and becomes 0.
th e axia l d ir ection of cylinde r bloc k ( 7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (Actually, however, the
swash plate angle is not set to 0)
q With centre line (X) of rocker cam (4) at a

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

q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
1. LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: LS mode selector pilot port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the pump delivery.
q This valve controls main pump delivery (Q)
according to differential pressure (EPLS)[=
PP – PLS], called the LS differential pressure
(the difference between main pump pressure
PP and control valve outlet port pressure PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
q The relationship between the LS differential
pressure between the main pump pressure
(PP) and LS pressure (PLS) (EPLS) [= (PP) –
(PLS)] and the pump delivery (Q) changes as
shown in the diagram according to LS selector
current (ISIG) of the LS-EPC valve.
q As (ISIG) changes from 0 to 1A, setting force
of the spring also changes. As the result, the
specified median of the pump delivery selector
point changes in the range of 1.18 to 2.65 MPa
{12 to 27 kg/cm2}.
Operation
1) When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is conducted to the larger
pressure (PLS) (LS pressure) from the outlet diameter end from the port (K).
port of the control valve brought to spring q The same pump pressure (PP) is conducted to
chamber (B), and main pump discharge pres- the smaller diameter end from the port (J).
sure (PP) brought to port (H) of sleeve (8). q According to the difference in the areas on
q Magnitude of the force resulting from this LS servo piston (12), the pressure moves in to the
pressure (PLS), force of spring (4) and the direction of minimizing the swash plate angle.
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q However, magnitude of the output pressure
(PSIG) (called the LS selector pressure) of the
EPC valve for the LS valve entering port (G)
also changes the position of spool (6). (Setting
force of the spring is changed)
q Before the engine is started, servo piston (12) is
pushed to the left. (See the figure to the right.)
q If the control lever is at the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit via the control valve spool)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
2) Action for the direction of maximizing the pump delivery
q When the difference between the main pump q If the output pressure of the EPC valve for the
pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is
words, LS differential pressure (EPLS) generated on piston (7).
becomes smaller (for example, when the area q If piston (7) is pushed to the right, setting force
of opening of the control valve becomes larger of spring (4) is weakened, changing the LS dif-
and pump pressure PP drops), spool (6) is ferential pressure (EPLS) [Difference between
pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D)
pressure (PLS) and the force of spring (4). and (E) of spool (6) are connected.
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the
pump delivery larger.
3) Action for the direction of minimizing the pump delivery
q When LS differential pressure (EPLS) becomes

larger (for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises) because of the rightward
move (it reduces pump delivery) of servo piston
(12), pump pressure (PP) pushes spool (6) to the
right.
q When spool (6) moves, main pump pressure
(PP) flows from port (C) to port (D) and from
port (K), it enters the large diameter end of the
piston.
q Main pump pressure (PP) also enters port (J)
of the small diameter end of the piston, but
because of the difference in area between the
large diameter end and the small diameter end
on servo piston (12), it is pushed to the right.
As the result, the servo piston (12) moves into
the direction of reducing the swash plate
angle.
q As LS selector pressure (PSIG) is input to port
(G), setting force of spring (4) is reduced.
4) When servo piston is balanced
q Let us take the area receiving the pressure at q Force of spring (4) is adjusted so that the bal-
the large diameter end of the piston as (A1), anced stop position of this spool (6) may be
the area receiving the pressure at the small determined when (PP) – (PLS) = 2.65 MPa {27
diameter end as (A0), and the pressure flowing kg/cm2} at the specified median.
into the large diameter end of the piston as q If (PSIG) [Output pressure of LS-EPC valve
(PEN). ranging from 0 to 2.9 MPa {0 to 30 kg/cm2}] is
q If the main pump pressure (PP) of the LS valve applied to port (G), the balanced stop position
and the combined force of spring (4) and LS changes in proportion to (PSIG) pressure in
pressure (PLS) are balanced, and the relation- the range of (PP) – (PLS) = 1.18 to 2.65 MPa
ship is (A0) × (PP) = (A1) × (PEN), servo pis- {12 to 27kg/cm2}.
ton (12) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
2. PC valve
PA: Pump port 1. Plug

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

q When the pump discharge pressure (PP1) value because of increased load, the controller
(self-pressure) and (PP2) (other pump pres- sends a command current to PC-EPC valve
sure) are high, the PC valve controls the pump solenoid in order to reduce the slope angle in
so that the volume of oil beyond the discharge proportion to reduction in the engine speed.
pressure-based specific flowrate may not be
conducted however you may increase the con-
trol valve stroke. Namely it is intended at con-
trolling the horse power for the pumps so that it
may not exceed the engine hose power.
q If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump delivery.
q And if the pump discharge pressure goes low,
it increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and the pump delivery (Q)
will becomes as shown in the diagram if the
relation is represented as the parameter the
current value (X) to be given to PC-EPC valve
solenoid.
q The controller continues counting the actual
engine speed.
q If the engine speed is slowed down due to
increased load, the controller reduces the
pump delivery to recover the speed.
Operation
1) When pump controller is normal
(1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) a Other pump's pressure denotes the pressure
q Command current (X) is being sent to PC-EPC of the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump's
q This command current acts on PC-EPC valve pressure is that of the rear pump.
to output the signal pressure in order to modify And for the rear pump pressure, the other
the force pushing piston (2). pump's pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined spool-pushing force is balanced by the
setting force of springs (4) and (6) as well as
the pump pressures (PP1) (self pressure) and
(PP2) (another pump's pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
Action of spring
q Load of springs (4) and (6) on the PC valve is q When pump pressures (PP1) and (PP2) are
determined by the swash plate position. small, spool (3) will be positioned in the left
q As servo piston (9) moves to right, spring (6) is side.
retracted. q Port (C) and (D) are connected, and the pres-
q If the servo piston moves further, it will be con- sure entering the LS valve becomes drain
tacted again seat (5) and spring (6) will be pressure (PT).
fixed. q If port (E) and port (G) of the LS valve are con-
q After that, spring (4) alone will operate. nected, the pressure entering the large diame-
q The spring load is changed by servo piston (9) ter end of the piston from port (J) becomes
as it extends or compresses springs (4) and drain pressure (PT), and servo piston (9)
(6). moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Accompanied with move of servo piston (9),
q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the
affected by the command current (X) to PC- spring force becomes weaker.
EPC valve solenoid. q As the spring force is weakened, spool (3)
q Port (C) of the PC valve is connected to port moves to the right, the connecting between
(E) of the LS valve. port (C) and port (D) is shut off and the pump
q Self pressure (PP1) enters port (B) and the discharge pressure ports (B) and (C) are con-
small diameter end of servo piston (9), and nected.
other pump pressure (PP2) enters port (A).
q As a result, the pressure on port (C) rises and

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

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

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to the
spool (3), so the relationship between the aver-
age pump pressure (PP1 + PP2)/2 and the
pump delivery (Q) moves from (A) to (B) as the
command current (X) is increased.
2) As the emergency pump drive switch is turned on due to failure on the pump controller
(1) When the main pump is under light load
q If there is a failure in the pump controller, the q Since the pressure on the small diameter end
emergency pump drive switch is turned on to of the piston large, servo piston (9) moves in
hand the control to the resistor side. the direction to make the discharge amount
q In this case, the power is directly supplied from larger.
the battery. The current, however, is too large
as is, so the resistor is set in between to con-
trol the current flowing to PC-EPC valve sole-
noid (1).
q The current becomes constant, so the force
pushing piston (2) is also constant.
q If the main pump pressures (PP1) and (PP2)
are low, the combined force of the pump pres-
sure and the PC-EPC valve solenoid (1) is
weaker than the spring set force, so spool (3)
is balanced at a position to the left.
q At this point, port (C) is connected to the drain
pressure of port (D), and the large diameter
end of the piston of servo piston (9) also
becomes the drain pressure (PT) through the
LS valve.
(2) When the main pump is under heavy load
q If the emergency pump drive switch is turned q The curve resulting when the emergency pump
on In the same way as in above, the command drive switch is ON is situated further to the left (B)
current (X) sent to PC-EPC valve solenoid (1) than when the pump controller is normal (A).
becomes constant.
q For this reason, the force of piston (2) pushing
spool (3) is constant.
q If main pump pressures (PP1) and (PP2)
increase, spool (3) moves further to the right
than when the main pump load is light, and is
balanced at the position in the diagram above.
q In this case, the pressure from port (B) flows to
port (C), so servo piston (9) moves to the right
(smaller pump delivery) and stops at a position
to the further to the right then when the load on
the pump is light.
q When the emergency pump drive switch is
turned on, too, the pump pressure (PP) and
pump delivery (Q) have a relationship as
shown with the curve in the diagram corre-
sponding to the current sent to the PC-EPC
valve solenoid through the resistor.
3. LS(PC)-EPC valve
C : To LS (PC) valve
P : From self pressure reducing valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
Function Operation
q The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion. 1) When signal current is 0
q When it receives signal current (i) from the (coil is de-energised)
controller, it generates the EPC output pres- q When there is no signal current flowing from
sure in proportion to the size of the signal, and the controller to coil (2), coil (2) is de-energised.
outputs it to the LS (PC) valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) closes and the pressurized oil from the
self pressure reducing valve does not flow to
the LS (PC) valve.
q The pressurized oil from the LS (PC) valve is
drained to the tank through port (C) and port (T).
2) When signal current is very small 3) When signal current is maximum

(coil is energised) (coil is energised)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energised, and a propulsion force energised.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and LS
shut off from port (C). (PC) valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves so that the propulsion force of not flow to the tank.
plunger (7) may be balance with pressure of
port (C) + spring load of spring (4).
q The circuit pressure between the EPC valve
and the LS (PC) valve is controlled in propor-
tion to the size of the signal current.
4. Variable volume valve
C: To PC valve 1. Plug
P: From self pressure reducing valve 2. Block
T: To tank 3. Piston
4. Spring
Function
q The variable volume valve stabilizes the EPC
valve's output pressure.
Operation
q Output pressure from EPC valve is conducted
to port (C) and as the result propulsion force of
piston (3) is increased by the load of spring (4).
q Piston (3) is pushed to the left, and volume of
port (C) is increased.
q The propulsion force of piston (3) becomes
smaller than the load of spring (4).
q Piston (3) is pushed toward right, and volume
of port (C) is decreased.
UEN02233-00

© 2007 KOMATSU
All Rights Reserved
30
UEN02234-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 14
Functions and operation by valve ................................................................................................................. 18
Merge-divider valve....................................................................................................................................... 33
Attachment circuit selector valve .................................................................................................................. 58
Holding valve ................................................................................................................................................ 60
Control valve 1
Outline
q The control valve consists of a 7-spool valve (6-
spool valve + boom Hi, arm Hi valve) and a set
of service valves. A merge-divider valve, a
back pressure valve, a boom drift preventive
valve are installed to it.
q Since all the valves are assembled together
with connecting bolts and their passes are con-
nected to each other inside the assembly, the
assembly is compact and easy to maintain.
A1: To bucket cylinder bottom PR: To solenoid valve, PPC valve, and EPC valve
A2: To L.H. travel motor PS: From merge-divide solenoid valve
A3: To boom cylinder bottom PST: From travel junction valve solenoid valve
A4: To swing motor PX1: From 2-stage relief solenoid valve
A5: To R.H. travel motor PX2: From 2-stage relief solenoid valve
A6: To arm cylinder head T: To tank
A-1: To boom cylinder bottom T1: To tank
A-2: To attachment 1 TS: To tank
A-3: To attachment 2 TSW: To swing motor S-port (suction side)
B1: To bucket cylinder head
B2: To L.H. travel motor 1. 6-spool valve
B3: 2. Cover A
B4: To swing motor 3. Cover B
B5: To R.H. travel motor 4. Boom Hi and arm Hi valve
B6: To arm cylinder bottom 5. Service valve 1
B-1: To arm cylinder bottom 6. Service valve 2
B-2: To attachment 1 7. Merge-divider valve
B-3: To attachment 2 8. Boom drift preventive valve
BP1: Boom raising PPC output pressure 9. Quick return valve
BP5: From 2-stage safety valve solenoid valve 10. Boom Hi valve check valve
BP6: From attachment select solenoid valve
P1: From bucket PPC and EPC valves
P2: From bucket PPC and EPC valves
P3: From L.H. travel PPC valve
P4: From L.H. travel PPC valve
P5: From boom PPC and EPC valves
P6: From boom PPC and EPC valves
P7: From swing PPC and EPC valves
P8: From swing PPC and EPC valves
P9: From R.H. travel PPC valve
P10: From R.H. travel PPC valve
P11: From arm PPC and EPC valves
P12: From arm PPC and EPC valves
P-3: From service 1 and PPC valves
PLS1: To front pump control
PLS2: To rear pump control
PP1: From front pump
PP2: From rear pump
PP1S: Pressure sensor mounting port
PP2S: Pressure sensor mounting port
PPS1: To front pump control
PPS2: To rear pump control
General view
Sectional view
(1/5)
1. Pressure compensation valve (Arm out)

2. Pressure compensation valve (R.H. travel
reverse)
3. Pressure compensation valve (Left swing)
4. Pressure compensation valve (Boom raise)
5. Pressure compensation valve (L.H. travel
reverse)
6. Pressure compensation valve (Bucket dump)
7. Pressure compensation valve (Boom Hi raise)
8. Variable pressure compensation valve (Ser-
vice 1)
9. Variable pressure compensation valve (Ser-
vice 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)
22. Spool (Service 1)
23. Spool (Boom Hi)
24. Spool (Bucket)
25. Spool (L.H. travel)
26. Spool (Boom)
27. Spool (Swing)
28. Spool (R.H. travel)
29. Spool (Arm)
30. Spool (Arm Hi)
Unit: mm

Free length × Installed 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}
(2/5)
1. Safety-suction valve (Arm out)

2. Suction valve (Right travel reverse)
3. Suction valve (Boom raise)
4. Suction valve (Left travel reverse)
5. Suction valve (Boom Hi raise)
6. Safety-suction valve (Service 1)
7. Safety-suction valve (Service 2)
8. 2-stage safety-suction valve (Service 1)
9. Safety-suction valve (Arm Hi in)
10. Safety-suction valve (Bucket curl)
11. Suction valve (Left travel forward)
12. 2-stage safety-suction valve (Boom lower)
13. Suction valve (Right travel forward)
14. Safety-suction valve (Arm in)
15. LS shuttle valve (Arm)
16. LS shuttle valve (Right travel)
17. LS select valve
18. LS shuttle valve (Boom)
19. LS shuttle valve (Left travel)
20. LS shuttle valve (Bucket)
21. LS shuttle valve (Service 1)
22. LS shuttle valve (Service 2)
23. LS check valve
24. Pressure relief plug
Unit: mm

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

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

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

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (Forward)
19. Spool
20. Suction valve (Forward)
21. Suction valve (Reverse)
22. Pressure compensation valve (Reverse)
Bucket valve
24. Pressure compensation valve (Curl)
25. Spool
26. Safety-suction valve (Curl)
27. Safety-suction valve (Dump)
28. Pressure compensation valve (Dump)
Unit: mm

Free length
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}
— {14.5 kg} deformed, replace
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}
(5/5)
Boom Hi and arm Hi valve
1. Boom Hi check valve

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

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

pump”.
2. Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to bal-
ance the load.
q When actuators are operated together, the
p r e s s u r e d i ff e r e n c e ( E P ) b e t w e e n t h e
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.
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
Functions and operation by valve 1

Hydraulic circuit diagram and the name of valves
1. Arm valve 42. 2-stage safety-suction valve

2. R.H. travel valve Set pressure: 1 stage: 28.4 ± 0.5 MPa{290 ± 5 kg/cm2}
3. Swing valve 2 stage: 14.7 ± 0.5 MPa{150 ± 5 kg/cm2}
4. Boom valve 43. Safety valve
5. L.H. travel valve Set pressure: 38.2 ± 0.5 MPa{390 ± 5 kg/cm2}
6. Bucket valve
7. Boom Hi valve
8. Arm Hi valve
9. Service valve 1
10. Service valve 2
11. Arm spool
12. R.H. travel spool
13. Swing spool
14. Boom spool
15. L.H. travel spool
16. Bucket spool
17. Boom Hi spool
18. Arm Hi spool
19. Service spool 1
20. Service spool 2
22. Variable pressure compensation valve
23. Suction valve
24. Check valve (for boom regeneration circuit)
25. Check valve (for arm regeneration circuit)
27. LS select valve
28. Merge-divider valve
29. Arm quick return valve
30. Self pressure reducing valve
31. Travel junction valve
32. Back pressure valve
33. Boom drift preventive valve
34. Boom Hi check valve
35. Main relief valve (bucket side)
Set pressure:
36.1 ± 0.25 MPa{367.5 ± 2.5 kg/cm2}(112l/min)
When digging force increased:
38.2 ± 0.25 MPa{389.5 ± 2.5 kg/cm2}(110l/min)
36. Main relief valve (arm side)
Set pressure:
36.1 ± 0.25 MPa{367.5 ± 2.5 kg/cm2}(112l/min)
When digging force increased:
38.2 ± 0.25 MPa{389.5 ± 2.5 kg/cm2}(110l/min)
37. Unload valve (bucket side)
Cracking pressure: 3.1 ± 0.5 MPa{32 ± 5 kg/cm2}
38. Unload valve (arm side)
Cracking pressure: 3.1 ± 0.5 MPa{32 ± 5 kg/cm2}
Set pressure: 17.2 ± 0.5 MPa{175 ± 5 kg/cm2}
Set pressure: 38.2 ± 0.5 MPa{390 ± 5 kg/cm2}
41. 2-stage safety-suction valve
Set pressure: 1 stage: 20.1 ± 0.5 MPa{205 ± 5 kg/cm2}
2 stage: 17.2 ± 0.5 MPa{175 ± 5 kg/cm2}
Unload valve
1. When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function Operation
q Drains an oil discharge for the portion of the q Pressure of pump circuit (3) is received by the
minimum pump swash plate angle while all end of valve (2).
control valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set pressure of LS circuit (1) is 0 MPa {0 kg/cm2}.
load of spring (5) inside the valve (this pres- q Pressurized oil of pump circuit (3) stops at
sure will be P1). valve (2), and the pressure rises as no relief is
q Since LS pressure is drained from the LS available.
bypass valve, LS pressure C tank pressure C q When this pressure becomes larger than the
0 MPa {0 kg/cm2}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes
from orifice (a) through port (c) and is drained
to the tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure – LS cir-
cuit pressure during unloading is larger than
the pump LS control pressure, the signal is
output to minimize the pump swash plate
angle.
q During operation (a work within a scope of dis- 2. Operation of relief valve

charge by a minimum swash plate angle), the q When the cylinder reaches the stroke end, the
discharge pressure for the portion of minimum main relief valve opens.
pump swash plate angle is set to LS pressure q The pump delivery (Q) is relieved to the
+ P1 pressure. tank.(See the system diagram)
q LS control differential pressure (EPLS) of dis- q The pump discharge pressure (PP) and LS
charge for the portion of minimum swash plate pressure (PLS) become approximately the
angle will be equal to P1 pressure. same as each has not flow at the upstream
and downstream of the spool, and LS differen-
tial pressure (EPLS) becomes 0 kg/cm2.
q As LS differential pressure (EPLS) is lower
than the LS set pressure of LS valve, LS valve
is actuated to maximize the pump swash plate
angle.
q Mechanically, operation of PC valve have the
prevalence to that of LS valve.
q The pump is held at a minimum swash plate
angle by the cut-off function of PC valve.
Introduction of LS pressure
1. Hydraulic pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
q Introduces the upstream pressure (spool
meter-in downstream pressure) of pressure
compensation valve (3) and leads to LS shuttle
valve (7) as the LS pressure.
q Connected to actuator port (B) through valve
(4), and makes LS pressure C actuator load
pressure.
q Inlet pore (a) inside main spool (2) has a small
diameter concurrently serving as a throttle.
Operation
q When main spool (2) is operated, the pump
pressure enters port (c) through inlet pore (a)
and is led to the LS circuit.
q When the pump pressures rises to reach the
load pressure of port (B), check valve (5)
opens and the pressurized oil flows.
LS bypass valve
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the cir-
cuit resistance between throttle (c) of main
spool (2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
Pressure compensation valve

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

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

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

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

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

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

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

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

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

neous operation of swinging and R.H. travel.
[(BP) pressure ON]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing spool
6. L.H. travel spool
7. Arm spool
8. LS shuttle valve
9. LS circuit
Self pressure reducing valve
Function
q Reduces the discharge pressure of the main
pump and supplies it as control pressure for
the solenoid valves, EPC valves, etc.
Operation
1. While engine is stopped
q Poppet (11) is pressed by spring (12) against
the seat and port (PR) is not connected to
(TS).
q Valve (14) is pressed by spring (13) against the
left side and port (P2) is connected to (TS).
q Valve (7) is pressed by spring (8) against the
left side and port (P2) is closed to (A2).
2. During neutral and when load pressure (P2) 3. When load pressure (P2) is high
is low q Load pressure (A2) increases with the opera-
a When load pressure (A2) is lower than self tion of digging, etc, and the pump discharge
pressure reducing valve output pressure (PR) increases accordingly.
q Pressure (P2) increases to [(Ød area × P2
q Valve (7) is pressed to the closing direction of pressure) = force of spring (8) + (Ød area × PR
circuit between ports (P2) and (A2) by spring pressure)], and valve (7) moves to the right to
(8) and under pressure (PR) (which is 0 MPa the stroke end.
{0 kg/cm2}). q As a result, opening between ports (P2) and
q When pressurized oil flows in from port (P2), a (A2) increases, and the pass resistance
balance is reached due to [(Ød area × P2 pres- reduces, reducing the engine horsepower loss.
sure) = force of spring (8) + (Ød area × PR q When pressure (PR) rises above the set pres-
pressure)]. sure, poppet (11) opens.
q Adjusts valve (7) opening to keep pressure q Pressurized oil flows from port (PR) to orifice
(P2) at a constant level over pressure (PR). (a) in spool (14), then flows to seal drain port
q When pressure (PR) rises above the set pres- (TS) from poppet (11) opening.
sure, poppet (11) opens. q Differential pressure is generated before and
q Pressurized oil flows from port (PR) to orifice after orifice (a) in spool (14) and then spool
(a) in spool (14), then flows to seal drain port (14) moves to close the pass between ports
(TS) from poppet (11) opening. (P2) and (PR).
q Differential pressure is generated before and q Pressure (P2) is reduced by the opening at this
after orifice (a) in spool (14) and then spool time and adjusted to a constant pressure (the
(14) moves to close the pass between ports set pressure) and supplied as pressure (PR).
(P2) and (PR).
q Pressure (P2) is reduced by the opening at this
time and adjusted to a constant pressure (the
set pressure) and supplied as pressure (PR).
4. When abnormally high pressure is gener-

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

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

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

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

(if equipped)
1. When arm OUT
Function
q This valve prevents the oil in the arm head
from leaking through spool (1) and the boom
from lowering under its weight while the arm
lever is not operated.
Operation
q When the arm OUT is operated, pressurized
oil from the control valve works on the ring-
shaped area (S) [= Ø(d1) area – Ø(d2) area]
caused by the difference between the outside
diameter (d1) of poppet (5) and the seat diam-
eter (d2) to move it to the left.
q Contracts spring (4) and poppet (5) moves to
the left.
q As a result, pressurized oil from the control
valve passes through the opening of poppet
(5) and flows to the arm cylinder head.
2. When the arm is in neutral
Operation
q Moves the lever to neutral with the arm
dumped.
q Pressurized oil flown inside poppet (5) from
orifice (a) of poppet (5) is closed by pilot piston
(2).
holding pressure of the arm cylinder head are
shut off.
q The holding pressure of arm cylinder head
works on ring-shaped area (S) caused by the
difference between outside diameter (d1) of
poppet (5) and seat diameter (d2) to move it to
the right.
q The sum of this force and the force of spring
(4) closes poppet (5).
holding pressure of the arm cylinder head are
shut off.
3. When arm IN
Operation
q If arm is set to IN, pilot piston (2) is pushed by
the pilot pressure from the PPC valve.
q Pressurized oil in chamber (b) inside the pop-
pet is drained through orifice (c).
q Pressurized oil of the arm head flows to orifice
(a) o chamber (b) o orifice (c) o drain (T),
and the pressurized oil in chamber (b) lowers.
q As the pressure of chamber (b) lowers under
the pressure of port (B), poppet (5) opens.
q Pressurized oil from port (B) is led to port (A)
and then flows to the control valve.
4. When abnormally high pressure is generated
q If abnormally high pressure is generated in the q If arm drift preventive valve (If equipped) is
boom cylinder bottom circuit, the pressurized installed to the arm cylinder head circuit, the
oil in port (B) pushes check valve (6) open, boom cylinder bottom circuit pressure force or
then safety valve (3) operates. arm cylinder head circuit pressure force,
whichever having higher pressurized oil,
pushes check valve (6) or (6A) open to actuate
safety valve (3).
Quick return valve

1. When arm OUT
Function
q When arm is set to out, large volume of oil
returns from the cylinder bottom.
q Reduces this pressure loss.
Operation
q When arm is set to out, pilot piston (1) is q Or (Ød2 pressure receiving force > Ød1 pres-
pushed by the pilot spool from the PPC valve. sure receiving force + spring force)
q Pressurized oil in chamber (b) inside the valve q Valve (2) is pressed to the left and pressurized
is drained through orifice (c). oil is led from port (A) to (B).
q Pressurized oil of the arm bottom side flows to q From port (B), pressurized oil is drained
orifice (a) o chamber (b) o orifice (c) o drain directly to the tank.
(T), and the pressure in chamber (b) lowers.
q If the pressure of chamber (b) drops lower than
that of port (A), pressure receiving force of the
pressure receiving portion [Ød2 area (S2)
(seat diameter area)] on the side of port (A)
increases by the sum of the pressure receiving
force of pressure receiving portion[Ød1 area
(S1)] on the chamber (b) side of valve (2) and
the spring force.
2. When the arm is in neutral
Operation
q Returning the lever to neutral reduces the pilot
pressure from the PPC valve to 0 MPa {0 kg/
cm2}.
q The pressurized oil that has flowed and been
drained through orifice (a) in valve (2) is closed
by pilot piston (1).
q The holding pressure on the arm bottom side
works on the difference between areas (S2)
and (S1) of valve (2) to the right.
q Valve (2) is closed by the total of this force and
the force of spring (3), so ports (A) and (B) are
shut off.
Lift check valve

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

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

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

setting
Spring (1) installed load is added with pilot
pressure (P) applied to the area of poppet (2)
diameter (d1), raising the set pressure to
higher level.
2-stage safety-suction valve

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

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

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

valve spool) q Regulates flow distribution to the service valve
B. Cylinder port when the service valve (attachment) and the
C. Load pressure of other work equipment work equipment valve (boom raising, etc.) are
operated together. (Equivalent surface area
1. Valve ratio variable)
2. Spring q Pressurized oil from the service valve spool is
3. Sleeve applied to the left side of valve (1) and is led to
4. Poppet chamber (g) via orifice (a).
5. Spring q LS pressure is led to chamber (e) through ori-
6. Screw fice (d).
7. Locknut q Pressurized oil of cylinder port is led to cham-
8. Cap ber (h) through passage (c) and orifice (f).
q The force of spring (2) acts on valve (1), and
the force of spring (5) acts on poppet (4).
q The force of spring (5) can be adjusted with
screw (6).
Operation when jointly operated with a high-load work equipment (such as the boom raising)
q Both of the pump discharge pressure (P) and q If the difference between the pump discharge
LS pressures are determined by other equip- pressure (P) and cylinder port pressure (B) is
ment's pressure, while cylinder port pressure larger than the force of spring (5), poppet (4) is
causes the attachment to operate. pressed to the right.
q If the difference between the pump discharge q Pump discharge pressure (P) flows to orifice
pressure (P) and cylinder pressure is smaller (a) and chamber (g) and is interconnected to
than the force of spring (5), the balance of cylinder port via passages (b) and (c).
forces applying to valve (1) may be expressed q Differential pressure is generated between the
with the following equation: upstream and downstream of orifice (a), which
reduces the pressure force in chamber (g).
P × A1 = P × A2 + LS(A2 – 1) + F q Force that presses valve (1) to the left is
reduced.
A1: Area of Ød1 q A state is reached where the area ratio has
A2: Area of Ød2 become smaller.
F: Force of spring q Valve (1) moves to the right, and the flow
P: Pump discharge oil pressure increases from the pump to the cylinder.
Attachment circuit selector valve 1
ACC: To accumulator 1. Spool

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

Free length × Installed Installed Installed If damaged or
Free length
3 Spool return spring Outside diameter length load load deformed, replace
834 N 667 N spring.
132 × 29 114.5
{85.0 kg}
— {68.0 kg}
Function
q When a breaker is installed, the return oil from
the breaker does not pass through the main
valve, but returns directly to the hydraulic tank.
q When other attachments (crusher, etc.) are
installed, the attachment and the main valve
are interconnected.
Operation
1. When attachment other than breaker is 2. When breaker is installed
installed q Pilot pressure (P1) from the attachment circuit
q Spool (1) is pressed to the left by the force of selector solenoid valve compresses spring (2),
spring (2). moving spool (1) rightward to the stroke end.
q Ports (ATT) and (V) are interconnected and q Ports (ATT) and (V) are shut off and ports
ports (ATT) and (T) are shut off. Attachment is (ATT) and (T) are interconnected.
thus interconnected to the control valve. q Pressurized oil returning from the breaker
returns directly to the hydraulic tank via port (T)
without passing through the control valve.
Holding valve 1
(For the boom and arm)
CY: To work equipment cylinder

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

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

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

valve to the cylinder
When the piping is free of breakage

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

q If piping (A) between the control valve and the
work equipment cylinder is broken, pressur-
ized oil in chamber (a) flows outside from the
damaged portion.
q Pressure force in chamber (a) drops.
q Pressure force in chamber (a) drops lower than
the combined pressure force of chamber (b)
and spring (6).
q Check valve (5) closes and chambers (a) and
(b) are cut off.
q Pressure for the work equipment cylinder is
held to prevent a sudden drop of the work
equipment.
3. When returning pressurized oil to the main

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

q Holding pressure of the work equipment cylin- q If piping (A) bursts between the control valve
der is led to chamber (b) and check valve (5) and the work equipment cylinder.
closes. q Pressurized oil in chamber (a) flows out to the
q Pilot pressure from the PPC valve is led to port bursted portion but resupplied from chamber
(PI) and reaches [Pilot Pressure > Force of (b).
Spring (3)] (area of d). q Since pressurized oil flows via opening (c) of
q Spool (1) moves to the right to the standby spool (1), a sudden drop of the cylinder is pre-
position. (1st stage stroke) vented.
q At this point, chambers (a) and (b) are not
interconnected.
q Pilot pressure further rises, and reaches [Pilot
pressure > Force of spring (2)] (area of d).
q Spool (1) moves further to the right, and cham-
bers (a) and (b) are interconnected. (2nd stage
stroke)
q Pressurized oil returns to the control valve
from the work equipment cylinder.
UEN02234-00

© 2007 KOMATSU
All Rights Reserved
66
UEN02235-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Valve control ................................................................................................................................................... 2
PPC valve ....................................................................................................................................................... 4
Solenoid valve............................................................................................................................................... 20
PPC accumulator .......................................................................................................................................... 22
Return oil filter............................................................................................................................................... 23
Center swivel joint......................................................................................................................................... 24
Travel motor .................................................................................................................................................. 25
Swing motor .................................................................................................................................................. 37
Hydraulic cylinder.......................................................................................................................................... 46
Valve control 1
1. Travel PPC valve B. Boom (RAISE)

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

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

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

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

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

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

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) via fine control hole
(f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
3) During fine control q Therefore, the pilot pressure oil from the self
(When control lever is returned) pressure reducing valve passes through fine
q When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from
is pushed up by the force of centering spring port (P1) to push the control valve spool.
(3) and pressure at port (P1). q The oil returning from chamber (B) passes
q Because of this, fine control hole (f) is con- from port (P2) through fine control hole (f') and
nected to drain chamber (D), and the pressur- flows to drain chamber (D).
ized oil at port (P1) is released.
q If the pressure of port (P1) is lowered exces-
sively, spool (1) is pushed down by metering
spring (2).
q Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
2. Travel signal/Steering function
Travel signal
q Travel signal if either of the L.H. or R.H. travel
levers is operated, the higher PPC output pres-
sure of both sides is output as the travel signal.
q Accordingly, whether the machine is travelling
is judged by the signal of port (P5).
Steering signal
q If the operation quantities of both levers are dif-
ferent from each other as in the steering opera-
tion, the higher one of the PPC output
pressures of both sides is output as the steer-
ing signal.
q Any signal is not output from port (P6) while
the machine is travelling straight (forward or
4) At full stroke
reverse) or in neutral.
q Lever (5) pushes down piston (4), and retainer
q Accordingly, whether the machine is being
(9) pushes down spool (1).
steered is judged by the signal of port (P6).
q Fine control hole (f) is shut off from drain
chamber (D), and is interconnected to pump
pressure chamber (PP).
Operation
1) When in neutral
q No output is made from respective output ports

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

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

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

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

2. Travel junction solenoid valve A1: To PPC valve
3. Merge-divider solenoid valve A2: To main valve (Travel junction valve)
4. Travel speed solenoid valve A3: To main valve (Merge-divider valve)
5. Swing brake solenoid valve A4: To both travel motors
6. Machine push-up solenoid valve A5: To swing motor
7. 2-stage relief solenoid valve A6: To 2-stage safety valve at boom cylinder head
A8: To main valve (2-stage relief valve)
P1: From main pump
ACC: To accumulator
1. Connector 4. Spool
2. Moving core 5. Block
3. Coil 6. Spring
Operation
When solenoid is de-energized When solenoid is energized
q Since the signal current does not flow from the q The signal current flows from the controller to
controller, solenoid (3) is de-energized. For this solenoid (3), and the latter is energized.
reason, spool (4) is pushed to the left by spring Accordingly, spool (4) is pressed against to the
(6). By this operation, the pass from port (P) to right side. By this operation, the pressurized oil
port (A) is closed and the pressurized oil from from the main pump flows through port (P) and
the main pump does not flow into the actuator. spool (4) to port (A), then flows into the actua-
At this time, the oil from the actuator is drained tor. At the same time, port (T) closes and stops
through ports (A) and (T) into the tank. the oil from flowing to the tank.
PPC accumulator 1
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas capacity: 300 cc (for PPC)
Return oil filter 1
For breaker
1. Drain plug Specifications

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

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

PB: From control valve Type : KMV200ADT-2
PI: From travel speed solenoid valve Theoretical displacement
T: To tank (Min.) : 130 cm3/rev
(Max.) : 200 cm3/rev
Rated pressure : 37.3 MPa {380 kg/cm2}
Rated speed
(Capacity min.) : 2,650 rpm
(Capacity max.) : 1,550 rpm
Brake release pressure : 0.98 MPa {10 kg/cm2}
Travel speed selector pressure
(differential pressure) : 0.78 MPa {8 kg/cm2}
1. Output shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. End cover
7. Slow return valve
8. Regulator piston
9. Plate
10. Disk
11. Check valve spring
12. Check valve
13. Counter balance valve spool
14. Spool return spring
15. Safety valve
16. Regulator valve
17. Spring
18. Brake spring
19. Brake piston
20. Check valve
Unit: mm
Free length
62.5 × 32.0 42.0 —
3.04 N 2.45 N spring.
{0.31 kg}
—
{0.25 kg}
98.1 N 78.5 N
23 Regulator piston spring 55.0 × 9.0 50.0
{10.0 kg}
—
{8.0 kg}
Operation of motor
1) At slow speed (motor swash plate angle at maximum)
q As the solenoid valve is de-energized, the pilot

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

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

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

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

q The brake valve consists of check valves (1), q Operating the travel lever conducts the pres-
counterbalance valve (2) and safety valve (3). surized oil from the control valve to port (PA).
q Functions and operations of respective compo- q The pressurized oil push-opens check valve
nents shall conform to the following. (12A) and then flows to motor outlet port (MB)
via motor inlet port (MA).
1. Counterbalance valve and check valve q The motor outlet side is closed by check valve
(12B) and spool (13), so the pressure at the
Function supply side rises.
q When traveling downhill, the machine travel
speed tends to get faster than the motor
(engine) speed because of the downward force
generated from its own weight.
q If the machine travels with the engine at low
speed, the motor may rotate without load,
causing the machine to run away, resulting in a
very dangerous situation.
q These valves are used to prevent above by
controlling the machine to travel according to
the engine speed (pump delivery).
Operation of brake during travelling downhill

q The pressurized oil on the supply side flows to q If indication of the machine runaway is sensed
chamber (S1) via orifice (E1) and orifice (E2) of while travelling downhill, the motor will be
the spool (13). caused to rotate without load to decrease the
q As the pressure in chamber (S1) goes above inlet side oil pressure.
the spool selector pressure, spool (13) is q Pressure in chamber (S1) is released through
pushed toward right. orifices (E1) and (E2).
q Port (MB) and port (PB) are connected, open- q As the pressure in chamber (S1) goes below
ing the motor outlet port side and starting the the spool selector pressure, spool (13) is
motor rotating. returned to the left by spring (14) and outlet
port (MB) is throttled.
q The pressure at the outlet port side rises, gen-
erating rotation resistance on the motor to pre-
vent the machine from running away.
q The spool moves to a position where the pres-
sure on outlet port (MB) can be balanced
against the machine's own weight and the inlet
port pressure.
q Oil flow from the outlet circuit is reduced to
ensure the travel speed corresponded to the
pump delivery.
2. Safety valve
(bidirectional 2-stage set safety valve)
Function
q As long as the machine travel is stopped (or it q As the pressure goes above the set pressure,
is travelling downhill), the counterbalance [Difference in areas of circles (D1) and (D2) ×
valve closes the inlet and outlet circuits of the Pressure] compresses spring (2).
motor. q Poppet (1) is moved leftward and the pressur-
q Since the motor is rotated by inertial force, ized oil flows into chamber (MA) of the oppo-
pressure in the motor outlet port side is abnor- site circuit.
mally increased, potentially resulting in dam-
ages on the motor and piping.
q The safety valve releases this abnormal pres-
sure to the inlet port side of the motor in order
to prevent damages to the equipment.
Bidirectional action
1) When pressure in chamber (MB) has
become high (when rotating clockwise)
q As long as the machine travel is stopped (or it
is travelling downhill), the check valve of coun-
terbalance valve closes chamber (MB) of the
outlet port circuit.
q The motor tries to continue rotation resorting to
inertial force, thus pressure on the outlet port
(MB) is increased.
2) When pressure in chamber (MA) has Operation of mechanism for varying set pres-
become high (when rotating counterclock- sure
wise) 1) When starting travel (high-pressure setting)
q As long as the machine travel is stopped (or it q As the travel lever is operated, the pressurized
is travelling downhill), the check valve of coun- oil from the pump moves spool (19) toward
terbalance valve closes chamber (MA) of the right.
outlet port circuit. q Above opens the pilot circuit to the safety
q The motor tries to continue rotation resorting to valve, conducting the pressurized oil to cham-
inertial force, thus pressure on the outlet port ber (J) through chamber (G) and passage (H).
(MA) is increased. q Piston (3) is pushed rightward, spring (2) is
compressed and the set load is increased.
q High pressure is turned on the safety valve,
providing a large tractional force to the valve.
q As the pressure goes above the set pressure,

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

ting)
q When the travel lever is placed in neutral, the
pressure in chamber (PA) drops and spool (24)
returns to the neutral position.
q When spool (24) is in the process of returning
to the neutral position, the pressurized oil in
chamber (J) flows to chamber (PA) through
passage (H) and chamber (G).
q Piston (3) moves to the left side, decreasing
the set load.
q The safety valve is caused to the low pressure
setting, thereby attenuating the shocks when
the speed is reduced.
Set pressure of safety valve
High pressure setting: 40.2 MPa {410 kg/cm2}

(at start of travel and during travel)
Low pressure setting: 27.5 MPa {280 kg/cm2}

(during stop)
Swing motor 1
Type: KMF230ABE-5
B: From swing holding brake solenoid valve Specifications

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

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

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

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

q This valve reduces the swing back generation q The motor rotation is reversed by the closing
in the swing body by the inertia of the swing pressure generated at port (MB). (1st time:
body, the backlash and rigidity of the machin- reverse rotation)
ery system, and the compression of the q Reversing pressure is generated on port (MA).
hydraulic oil when the swing is stopped. Pressure (MA) is conducted to chamber (a).
q The valve contributes in preventing collapsing q The pressure compresses spring (3) by use of
of load when the swing is stopped and also the difference in areas of circles (φD3 > φD4) of
contributes in reducing cycle time (enhances spool (2) and moves spool (2) to the right side.
the positioning performance, enabling you to q Port (MA) o chamber (b) will be intercon-
proceed to the next work quicker than ever). nected.
q Then ports (b) and (f) will be interconnected
Operation through the drilled hole (h) on spool (5). This
1. When port (MB) brake pressure is gener- interconnection bypasses the reversing pres-
ated sure on port (MA) to port (T), thereby prevent-
q Pressure (MB) is conducted to chamber (d) via ing the reverse rotation of the 2nd time.
notch (g).
q The pressure compresses spring (6) by use of
the difference in areas of circles (φD1 > φD2) of
spool (5) and moves spool (5) to the left side.
q Port (MB) o chamber (e) will be intercon-
nected.
q Since pressure (MA) is lower than the set pres-
sure of spring (3), spool (2) does not move and
the pressurized oil is kept in. Thus the braking
force is ensured.
Hydraulic cylinder 1
Boom cylinder
Arm cylinder
Bucket cylinder
Unit: mm
Cylinder
size Shaft Hole clearance limit
–0.036 +0.261 0.083 –
Boom 100 0.412
Clearance between –0.090 +0.047 0.351
1 piston rod and bushing
Replace bushing
–0.036 +0.263 0.084 –
Arm 120 0.412
–0.090 +0.048 0.353
–0.036 +0.257 0.083 –
Bucket 110 0.447
–0.090 +0.047 0.347
–0.036 +0.169 0.136 –
Boom 110 —
–0.090 +0.100 0.259
Clearance between
–0.036 +0.169 0.136 –
2 piston rod support pin Arm 110
–0.090 +0.100 0.259
—
and bushing
–0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277 Replace pin or
–0.036 +0.190 0.106 – bushing
Boom 100 —
Clearance between –0.090 +0.070 0.280
cylinder –0.036 +0.195 0.135 –
3 bottom support pin and
Arm 110
–0.090 +0.099 0.285
—
bushing –0.036 +0.187 0.133 –
Bucket 100 —
–0.090 +0.097 0.277
UEN02235-00

© 2007 KOMATSU
All Rights Reserved
48
UEN02236-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of components............................................................................................................................. 4
Work equipment 1
Unit: mm
Clearance between connecting pin size clearance limit
Shaft Hole
1 and bushing of revolving frame
and boom –0.036 +0.173
120 0.137 – 0.263 1.0
–0.090 +0.101
Clearance between connecting pin –0.036 +0.180
2 and bushing of boom and arm 120
–0.090 +0.112
0.148 – 0.270 1.0
Clearance between connecting pin –0.036 +0.172 Replace

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

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

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

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

Adjust shims
8 Bucket clearance (b) 2.0
Dimensions of components 1
1. Dimension of arm
Unit: mm
PC400-8 PC450-8
No. Measuring position Standard Tolerance Standard Tolerance
size Shaft Hole size Shaft Hole
–0.036 +0.1 –0.036 +0.1
1 — φ110
–0.090 0
φ110
–0.090 0
+1.5 +1.5
Arm side 129.3 129.3
2 0 0
Cylinder head side 126 ±1.2 126 ±1.2
+0.5 +0.5
Boom side 355 355
0 0
3
–0.3 –0.3
Arm side 351 351
–0.8 –0.8
–0.036 +1.0 –0.036 +0.1
4 — φ120
–0.090 0
φ120
–0.090 0
5 — 514.8 — 570.6 —
6 — 195 — 208.2 —
7 — 1,038 — 1,132.2 —
8 — 3,375 — 3,375 —
9 — 2,977.5 — 2,975.1 —
10 — 502 — 506.8 —
11 — 720 — 720 —
12 — 719 — 719 —
13 — 537.1 — 537.1 —
14 — 1,850 — 1,817 —
–0.036 +0.1 –0.036 +0.1
15 — φ100
–0.090 0
φ100
–0.090 0
+1 +1
Bucket side 371 371
0 0
16
Link side 370 ± 0.5 370 ±0.5
–0.036 +0.1 –0.036 +0.1

17 — φ100
–0.090 0
φ100
–0.090 0
0 0
Arm itself 355 355
18 –0.5 –0.5
When press fitting bushing 370 — 370 —
Min. 1,870 — 1,870 —
19
Max. 3,140 — 3,140 —
2. Dimension of bucket
Unit: mm
PC400-8, PC400LC-8 PC450-8, PC450LC-8
No. Measuring position
Standard size Tolerance Standard size Tolerance
1 — 534.1 ±0.5 534.1 ±0.5
2 — 56.3 ±0.5 56.3 ±0.5
3 — 96°1' — 94°14' —
4 — 537.1 — 537.1 —
5 — 1,839 — 1,806 —
6 — 190 — 198 —
7 — — — — —
8 — 62°1' — 46°1' —
+0.1 +0.1
A — φ140.1
0
φ140.1
0
+0.063 +0.063
9 B — φ130
+0.054
φ130
+0.054
+0.1 +0.1
C — φ100
0
φ100
0
+1 +1
10 — 371
+0
371
+0
A — 57 — 58 —
11
B — 72 — 72 —
12 — 144 — 144 —
+0.5 +0.5
13 — 562.5
–2.5
562.5
–2.5
14 — φ26 — φ26 —
A — φ165 — φ165 —
15
B — — — — —
16 — φ230 — φ230 —
17 — 146.1 — 135.5 —
18 — 137.6 — 142 —
19 — R115 — R115 —
20 — R85 — R85 —
21 — 410 ±1 410 ±1
22 — 64 — 64 —
UEN02236-00

© 2007 KOMATSU
All Rights Reserved
8
UEN02237-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Cab and its attachments
Air conditioner piping ...................................................................................................................................... 2
Air conditioner piping 1
1. Receiver tank A: Fresh air

2. Condenser B: Re circulated air
3. Air conditioner compressor C: Hot/cool air
4. Refrigerant piping
5. Hot water pick-up piping
6. Hot water return piping
7. Air conditioner unit
8. Duct
UEN02237-00

© 2007 KOMATSU
All Rights Reserved
4
UEN02238-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Electrical system
Engine control ................................................................................................................................................. 2
Electronic control system .............................................................................................................................. 13
Monitor system.............................................................................................................................................. 38
Sensor........................................................................................................................................................... 65
KOMTRAX terminal system .......................................................................................................................... 68
Engine control 1
1. Battery relay Outline

2. Battery q The engine can be started and stopped with
3. Starting switch only starting switch (3).
4. Fuel control dial
5. Starting motor
6. Engine throttle controller
7. Pump controller
Operation of system
Starting engine Stopping engine
q When the starting switch is turned to the q When detecting that the starting switch is set to
“START” position, the starting signal flows to the “STOP” position, the engine controller cuts
the starting motor. Then, the starting motor the fuel injection to stop the engine.
turns to start the engine.
When it happens, the engine controller checks

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

q The fuel control dial sends a signal voltage cor-
responding to the rotation angle to the engine
controller.
q The pump controller receives the fuel dial posi-
tion information from the engine controller
through the network.
q The pump controller calculates the engine
speed in accordance with the working mode,
the deceleration, and the like, and sends an
instruction to the engine controller.
q The engine controller determines the fuel injec-
tion quantity based on the instruction received
from the pump controller.
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
q A potentiometer is installed under the knob. As
the knob is turned, the potentiometer shaft is
turned.
q As the potentiometer shaft is turned, the resis-
tance of the variable resistor in potentiometer
(5) changes and a throttle signal is sent to the
engine controller.
q The hatched area in the graph shown at right is
the abnormality detection area.
Engine controller
q Meanings of signal classes in the terminal CN-CE01

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

6
Swing control function
Travel control function
8
Attachment flow control and circuit selector function
(if equipped)
Self-diagnosis function
a For the self-diagnosis function, see “Troubleshooting“.
Machine control system diagram
1. Engine and pump composite control function
Function 1) Control method in each mode

q This function allows the operator to select P and E modes
proper engine torque and pump absorption q Matching point in P mode: Rated speed
torque according to the type of work. Four
modes are provided: P, E, B and L. Using the Mode Matching point
work mode switch on the monitor panel, the 246.3 kW/1,850 rpm
operator is required to select one of them. P
{330 HP/1,850 rpm}
q The pump controller detects the speed of the 213.3 kW/1,720 rpm
engine governor set with the fuel control dial E
{286 HP/1,720 rpm}
and the actual engine speed (N) and controls
them so that the pump will absorb all the
torque at each output point of the engine, q If the pump load increases and the pres-
according to the pump absorption torque set in sure rises, engine speed (N) lowers. At
each mode. this time, the controller lowers the pump
discharge so that the engine speed will be
near the maximum output point.
If the pressure lowers, the controller
increases pump discharge (Q) so that the
engine speed will be near the maximum
output point.
By repeating these operations, the con-
troller constantly uses the engine near the
maximum output point.
B and L modes
Mode B mode L mode

Partial output point 82% 61%
Mode Matching point

194.9 kW/1,730 rpm
B
{261 HP/1,730 rpm}
150.8 kW/1,250 rpm
L
{202 HP/1,250 rpm}
q In B or L mode, the controller controls the

pump absorption torque through the pump
and engine compound control function to
decrease engine speed (N) while main-
taining engine torque (T) constant along
the constant horsepower curve. This
ensures reduced fuel consumption.
2) Function to control pump during travel 3) Function to control when emergency pump
q Traveling the machine in E or B mode drive switch is turned on
leaves the working mode unchanged, but q Even if any abnormality occurs in the controller
raises the pump absorption torque and or sensor, setting emergency pump drive
engine speed (N) to values same as those switch (1) to the “ON” position activates the
in P mode. machine with an absorption torque approxi-
q If the machine travels in L mode, the work- mately equivalent to that in E mode.
ing mode and engine speed (N) do not In this case, a constant current flows from the
change, but the pump absorption torque is battery to the EPC valve for PC and therefore,
increased. the oil pressure is sensed by only the EPC
valve for PC.
2. Pump and valve control function
Function
q The machine is matched to various types of
work properly with the 2-stage relief function to
increase the digging force, etc.
1) LS control function 3) 2-stage relief function

q Depending on the operation condition of q The relief pressure in the normal work is
the actuator, this function changes the 34.8 MPa {355 kg/cm 2 }. If the 2-stage
pressure output from the LS-EPC valve to relief function is turned on, however, the
LS valve to change the change point (LS relief pressure rises to about 37.2 MPa
set differential pressure (DLS)) of the {380 kg/cm 2 }. By this operation, the
pump discharge in the LS valve. hydraulic force is increased further.
q By this operation, the start-up time of the
pump discharge is optimized and the com- Operating condition for turning on
Relief pressure
posite operation and fine control perfor- 2-stage relief function
mance is improved. • During travel
• When swing lock switch is turned to 34.8 MPa
the ON position {355 kg/cm2}
• When boom is lowered O
• When power maximizing function is 37.2 MPa
turned on {380 kg/cm2}
• When L mode is operated
2) Cut-off function
q This function increases PC-EPC current
(J) to reduce the flow rate in the relief
state, improving fuel consumption.
Operating condition for turning on cut-off function

When the average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} with the power
maximizing function off.
The cut-off function does not work, however, while the
machine is travelling in P mode, swing lock switch is in
the “ON” position.
3. Power maximizing and machine push-up function
Function
q The power maximizing function allows the
operator to increase power for a certain time
by operating the left knob switch.
q The machine push-up function allows the oper-
ator to increase the boom pushing force by
operating the machine push-up switch.
1) Power maximizing function 2) Machine push-up function

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

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

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

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

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

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

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

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

q If the controller, etc. has a problem, the
swing holding brake does not work nor-
mally, and the machine cannot swing, the
swing lock can be reset with the swing
holding brake release switch.
q Even if the swing holding brake release
switch is turned on, if the swing lock
switch is turned on, the swing brake is not
released.
q If the swing lock is reset, only the hydrau-
lic brake is applied by the safety valve.
Note that if swinging is stopped on a
slope, the upper structure may swing by
its gravity.
Swing
holding ON OFF
brake (when controller has (when controller is nor-
release trouble) maly)
switch
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing lock
Swing holding
is turned is can- is turned
brake brake is
on. celed. on.
turned on.
7. Travel control function
Function
q The machine is provided with a function that
ensures travel performance best fit to the type
of work and jobsite by controlling pumps during
travel or allowing operator to change travel
speed automatically or manually.
1) Pump control function during travel 2) Travel speed change function

q If the machine travels in a work mode 1] Manual change with travel speed switch
other than P mode, the work mode and If one of Lo, Mi and Hi is selected with the
the engine speed are kept as they are and travel speed switch, the pump controller
the pump absorption torque is increased. controls the pump capacity and motor
q For details, see "Engine and pump com- capacity at each gear speed as shown
posite control function." below to change the travel speed.
Mi (Mid-
Travel speed Lo (Low Hi (High
ium
switch speed) speed)
speed)
Pump capacity (%) 90 80 100
Motor capacity Max. Max. Min.
Travel speed
3.0 4.2 5.5
(km/h)
2] Automatic change by engine speed

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

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

1) PPC oil pressure switch
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q The junction block has 7 PPC oil pressure
switches.
q This sensor detects the operating condition of
each actuator by the PPC pressure and trans-
mit it to the pump controller.
2) Oil pressure sensor
1. Sensor
2. Connector
Function q The relationship between the pressure applied

q The pump pressure sensor is installed to the to sensors (P) (MPa {kg/cm2}) and output volt-
input circuit of the control valve. age (E) (V) is shown in the figure below.
q It converts the pump discharge pressure into a E = 0.08 {0.008} x P + 0.5
voltage and transmits it to the pump controller.
Operation
q The oil pressure is applied to the diaphragm of
the oil pressure sensor from the pressure
intake part, the diaphragm is deformed.
q The deformation in the diaphragm causes the
resistance of the gauge to change. This
causes a change in the output voltage, which
is transmitted to the amplifier (voltage ampli-
fier).
q The amplifier magnifies output voltage (E) and
transmits it to the pump controller.
3) Pump pressure sensor (high pressure)
1. Sensor
2. Connector
Operation
q The relationship between the pressure applied
to sensors (P) and output voltage (E) is shown
in the figure below.
4) Pump controller
CN-C01
CN-C01 Input/
Input/ Pin No. Signal name
Pin No. Signal name output
output 52 Service switch Input
1 PWR_IN_BATT Input 53 Boom raise pressure switch Input
2 GND_PWR Input 54 NC(*) —
3 Washer motor output 55 Travel switch Input
4 PWR_IN_BATT Input 56 Wiper limit switch Input
5 GND_PWR Input 57 Window limit switch Input
6 NC(*) — 58 Machin select 4 Input
7 NC(*) — 59 NC(*) —
8 NC(*) — 60 Start switch Input
9 PWR_OUT_5V_0 output 61 NC(*) —
10 NC(*) Input 62 NC(*) Input
11 NC(*) Input 63 NC(*) —
12 NC(*) Input Input/
64 COMM_CAN_L_0
13 NC(*) Input output
14 Boom lower switch Input 65 GND_SIG_A —
15 Arm dump switch Input 66 NC(*) —
16 Swing pressure switch Input 67 NC(*) —
17 Arm curl pilot sensor Input 68 R pump pressure sensor Input
18 GND_SIG_A Input 69 NC(*) —
19 Swing lock switch Input 70 NC(*) —
20 NC(*) — 71 NC(*) Input
21 Machin select 2 Input 72 NC(*) —
22 NC(*) — 73 Bucket curl pilot sensor Input
23 NC(*) — 74 Overload pressure sensor —
24 PWR_CTR_KEY — 75 Wiper limit switch (P) Input
25 NC(*) — 76 NC(*) —
26 NC(*) — 77 Machin select 3 Input
27 NC(*) — 78 Overload caution enable switch —
28 NC(*) — 79 Start switch (ACC) Input
29 Hydraulic–oil temperature Input 80 NC(*) —
30 NC(*) — 81 GND_SIG_D —
31 NC(*) — *: Never connect to NC or malfunctions or failures will
32 NC(*) — occur.
33 NC(*) —
34 Bucket dump pressure switch Input
35 NC(*) —
36 Travel steering switch Input
37 GND_SIG_D —
38 Swing prolix switch Input
39 Machin select 5 Input
40 Machin select 1 Input
41 Knob switch Input
42 NC(*) —
43 PWR_CTR_KEY Input
44 GND_SIG_P Input
Input/
45 COMM_CAN_H_0
output
46 GND_SIG_A Input
47 GND_SIG_A —
48 NC(*) —
49 F pump pressure sensor Input
50 NC(*) —
51 NC(*) —
CN-C02
Input/
Pin No. Signal name
output
82 NC(*) —
83 NC(*) —
84 NC(*) —
85 NC(*) —
86 Att circuit change solenoid output
87 Travle speed solenoid output
88 NC(*) output
89 NC(*) —
90 NC(*) —
91 NC(*) —
92 NC(*) —
93 NC(*) —
94 NC(*) —
95 NC(*) output
96 PCQ–EPC (F) output
97 Att flux limit epc output
98 NC(*) —
99 NC(*) —
100 NC(*) —
101 Swing brake solenoid output
102 NC(*) —
103 NC(*) —
104 NC(*) —
105 NC(*) —
106 NC(*) —
107 NC(*) —
108 Battery relay output
109 2-stage relief solenoid output
110 Travel valve solenold output
111 NC(*) —
112 Merge-divider solenoid (Main) output
113 NC(*) —
114 Wiper motor (–) output
115 GND_ACT Input
116 Solenoid power supply Input
117 GND_ACT Input
118 Solenold power supply Input
119 Wiper motor (+) output
120 GND_ACT Input
121 Solenoid power supply Input
*: Never connect to NC or malfunctions or failures will
occur.
Monitor system 1
q The monitor system notifies the operator of

machine status. It monitors the condition of the
machine with sensors installed on various
parts of the machine, processes and immedi-
ately displays the obtained information on the
panel. The information that appears on the
panel is roughly divided as follows.
1. Alarms that are issued when the machine
has troubles
2. Machine status, including coolant temper-
ature, hydraulic oil temperature and fuel
level
q The machine monitor also has various mode
selector switches and functions to operate the
machine control system.
******
Machine monitor 1
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electric parts.
q The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
Input and output signals CN-CM03

Input/
CN-CM01 Pin No. Signal name
output
Input/ RS232C CD for communica-
Pin No. Signal name 1 Input
output tion terminal
Battery power (+24V con- RS232C RXD for communica-
1 Input 2 Input
stantly) tion terminal
Battery power (+24V con- RS232C SG for communica-
2 Input 3 —
stantly) tion terminal
3 Battery power GND — Signal GND for communication
4 Battery power GND — 4 —
terminal control
Input/ Communication terminal selec-
5 Wake-up 5 Input
Output tion signal
6 Relay output Output RS232C RTS for communica-
6 Output
7 — — tion terminal
8 NC(*) — RS232C TXD for communica-
7 Output
9 Fuel level Input tion terminal
10 NC(*) — RS232C DTR for communica-
8 Output
11 Charge amount Input tion terminal
12 Chassis analog signal GND — RS232C DSR for communica-
9 Input
13 Light switch Input tion terminal
14 Key switch (ACC) Input RS232C CTS for communica-
10 Input
tion terminal
15 Key switch (C) Input
RS232C RI for communication
16 Preheating Input 11 Input
terminal
17 NC(*) —
Power GND for communication
18 NC(*) — 12 —
terminal
*: Never connect to NC or malfunctions or failures Input CH1 for communication
will occur. 13 Input
terminal status
Output for communication ter-
14 Output
CN-CM02 minal power control
Input/ Output CH1 for communication
Pin No. Signal name 15 Output
output terminal control
1 NC(*) — Output CH2 for communication
16 Output
2 Engine oil level sensor Input terminal control
3 Coolant level sensor Input Input CH2 for communication
17 Input
4 Air cleaner clogging sensor Input terminal status
5 Swing lock Input Electric power supply for com-
18 Output
6 NC(*) — munication terminal
7 NC(*) —
8 CAN terminating resistance —
Input/ CN-CM04
9 CAN_H
Output Input/
Pin No. Signal name
Input/ output
10 CAN_L
Output 1 NC(*) —
Input/ 2 NC(*) —
11 NC(*)
Output 3 NC(*) —
Input/ 4 NC(*) —
12 NC(*)
Output 5 NC(*) —
*: Never connect to NC or malfunctions or failures 6 NC(*) —
will occur. 7 NC(*) —
8 NC(*) —
9 NC(*) —
10 NC(*) —
11 NC(*) —
12 NC(*) —
*: Never connect to NC or malfunctions or failures
will occur.
CN-CM05
Input/
Pin No. Signal name
output
Electric power supply for cam-
1 Output
era
2 Camera NTSC signal input 1 Input
Electric power supply GND for
5 —
camera
6 Camera signal GND1 —
Monitor control, display portion 1

Monitor portion
1. Hydraulic oil temperature monitor

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

q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on).
Products having 10 or less black or bright
spots conform the product specification; such
the condition is quite normal.
q Battery voltage may suddenly drop at engine-
start due to ambient temperature or the condi-
tion of the battery. The machine monitor dis-
play may temporarily disappear if it happens; it
is quite normal.
q Continuous operation of the machine monitor
may display blue bright spots on the screen
having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this rea-
son, blue spots will not cause any problem
(since the liquid crystal lights up red, blue, and
green spots when displaying white).
Monitor items and display
Symbol Display item Display method
Swing holding brake

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

Automatic preheating symbol keeps lighting up for up to about 30
seconds and then goes off after engine starts.
Preheating Time after setting Display of symbol
Manual preheating 0 – 30 sec ON

30 – 40 sec Flashes
After 40 sec OFF
Power Max. switch Display of symbol

Keeps lighting up.
Power Max. While pressed Goes off after about 9 sec. if switch
is kept pressed.
While released Kept turned OFF.
Engine coolant
temperature
Hydraulic oil
temperature
Fuel level See gauge display on next page.
PTO oil
temperature
Engine
oil pressure
The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Temperature or vol-
Gauge Range Indicator Buzzer sound
ume
A1 105 Red Q
A2 102 Red
Engine coolant tem- A3 100 Off
perature
(°C) A4 80 Off
A5 60 Off
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil tempera- B3 100 Off
ture
(°C) B4 85 Off
B5 40 Off
B6 20 White
C1 467 Off
C2 381 Off
C3 295 Off
Fuel level (l)
C4 147.5 Off
C5 114 Off
C6 80.5 Red
Checks before starting (all symbols light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic
oil temperature gauge and the hydraulic oil temperature monitor disappear and the following symbols are
displayed.
Check before starting While engine is While engine is

Symbol Display item
item stopped running
Lights up and buzzer

Engine oil pressure q —
sounds when abnormal.
Lights up when
Battery charge q —
abnormal.
Lights up and buzzer Lights up and buzzer

Radiator coolant level q sounds when abnormal. sounds when abnormal.
Lights up when
Engine oil level q abnormal.
—
Lights up when
Air cleaner clogging q —
abnormal.
Notice lamp (yellow)/Warning lamp (red).

Maintenance Lights up for only 30 seconds after starting
switch is turned ON.
Symbols appear in the order in which they occur

from the upper left. When symbols are displayed, if
the hydraulic oil temperature is high or low, only its
symbol is displayed.
Condition of hydraulic oil Color of symbol

Low temperature (below B6 or Black on white back-
equivalent) ground
Normal (B6 – B2) No display
White on red back-
High temperature (above B2)
ground
Display
Symbol Display item Display range Display method
category
Green:
Displays state of message
KOMTRAX There is unread message.
(for only machine equipped
message Blue:
with KOMTRAX).
There is unreturned message.
Air conditioner/
ON OFF Displays operating condition.
Heater
INT ON OFF
Wiper Displays set condition.
Monitor
Working mode P, E, L, B, ATT Displays set mode.
Lo Mi Hi
Travel speed Displays set speed.
Auto-deceleration ON OFF Displays operating condition.
Displays average work load in

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

Service Service meter
While service meter is working (Changes to clock if F4 is
meter indicator
depressed.)
Displays time.
12-hour display
Clock Clock (Changes to service meter if
24-hour display F4 is depressed.)
Switches 1
1. Buzzer cancel switch Auto-deceleration switch

2. Auto-deceleration switch The auto-deceleration switch toggles the auto-
3. Guidance icon deceleration function on and off. When the working
4. Function switch mode is switched, it is automatically set to ON.
5. Working mode selector switch When it is set to ON, the auto-deceleration monitor
6. Travel speed selector switch appears.
7. Window washer switch a The auto-deceleration function does not work
8. Wiper switch in L mode.
9. Air conditioner control switch
Guidance icon and function switch
Buzzer cancel switch The function switches differ depending on the
Pressing this switch when the alarm buzzer is mak- screen display. Each guidance icon shows the func-
ing sound stops the alarm buzzer. tion of the switch below it.
If a new abnormality is detected, the alarm buzzer Switches with no guidance icon are disabled.
sounds. The functions shown by the guidance icons are as
Depending on the alarm buzzer type, it does not shown in the table below.
stop even if you press the buzzer cancel switch.
Symbol Switch Item Function
F6 Enter Enters selected/set item.
F5 Return Returns to previous screen.
F3 Select camera screen Selects camera screen.
F4 Select service meter/clock Selects service meter and clock alternately.
F5 Select maintenance screen Selects maintenance screen.
F6 Select user mode screen Selects user mode screen.
Selects item on left side (Selects right end item after left
F3 Select item
end item).
Selects item on right side (Selects left end item after right
F4 Select item
end item).
Selects item on lower side (Selects top item after bottom
F3 Select item
item)/Resets holding of monitoring.
Selects item on upper side (Selects bottom item after top
F4 Select item
item)/Holds monitoring.
Selects page on lower side (Selects top page after bottom
F1 Select item
page).
Selects page on upper side (Selects bottom page after top
F2 Select item
page).
F1 Display No. 1 camera screen Selects No. 1 camera screen.
Display No. 1 and No. 2

F4 Displays No. 1 and No. 2 camera screens simultaneously.
camera screens
Returns selected item to default setting. (Used for
F2 Return to default setting
adjustment of screen.)
Starts operation. (Used to start measurement of split fuel
F1 Start
consumption on fuel consumption display screen.)
Stops operation. (Used to stop measurement of split fuel
F1 Stop
consumption on fuel consumption display screen.)
F1/F2 Clear Clears selected/displayed item
F1 Set Executes setting.
Working mode selector switch Travel speed selector switch

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

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

Stowing stopped or now
None OFF
stowing
Wiper symbol +
F5 : Returns to the working mode selector screen. INT Intermittent actuation
INT
F6 : Specifies the breaker mode. Wiper symbol +
ON Continuous actuation
ON
q If B mode is specified as a working mode when
you start the monitor, the buzzer sounds and
the following message appears. Air conditioner control switch
To operate the air conditioner, use the air condi-
tioner control switches.
F5 : Starts up in E mode.
F6 : Starts up in B mode.
9a : Specifies airflow Camera screen display function 1

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

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

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

the working mode selector switch, travel speed
selector switch, auto-deceleration switch,
buzzer cancel switch, wiper switch, and win-
dow washer switch are enabled.
q Changing the working mode or travel speed
returns to the normal screen.
q If an abnormality corresponding to an alarm
item with the camera screen displayed, the
alarm monitor appears on the upper left of the
screen. If it appears, return to the normal
screen with F5 to check the alarm display.
q If an abnormality corresponding to an error
item with the camera screen displayed, the
error monitor appears on the upper left of the
screen. If it appears, you must move the
machine to safe posture immediately and
make inspections.
q If you do not operate the lever at least 10 sec.
after the error monitor starts to blink, the
screen switches to the normal screen.
Service meter/time selector function 1

q Pressing F4 on the normal screen when the
service meter is displayed in the top center of
the screen switches the display to the time,
and doing so when the time is displayed
switches the display to the service meter.
Maintenance function 1
q Pressing F5 on the normal screen switches to
the maintenance screen.
F5 : Cancels the reset to return to the maintenance

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

and replacement intervals. The time remaining
to maintenance is reduced as the machine is
operated.
Replacement interval
No. Item
(Hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel main filter 1000
41 Fuel prefilter 500
F1 : Displays the next page.
04 Hydraulic filter 1000
Displays the top page when the last page is
05 Hydraulic tank breather 500
displayed.
06 Corrosion resistor 1000(*)
F2 : Displays the previous page.
07 Damper case oil 1000
Displays the last page when the top page is
displayed. 08 Final case oil 2000
F3 : Selects (highlights) an item one down. 09 Machinery case oil 1000
F4 : Selects (highlights) an item one up. 10 Hydraulic oil 5000
F5 : Returns to the normal screen. *: If equipped (To be determined)
F6 : Switches to the maintenance time reset screen.
No operation at least 30 sec. : Returns to the nor- q The content of the caution display differs
mal screen. according to the remaining time. The relation-
ship is as shown in the table below.
q If the remaining time on the maintenance table
screen is less than 30 hours, the relevant items Display Condition
are highlighted in yellow, and if 0 hours, they Remaining time for mainte-
are done in red. None nance for all items is more
q On the maintenance time reset screen, reset than 30 hours.
the remaining time for the selected item to There is one or more items
Notice display (black sym-
return to the default. with less than 30-hour
bol displayed on yellow
remaining time for mainte-
q If switch F6 is not kept pressed for at least 1.5 background)
nance.
seconds, the switch operating sound can be
There is one or more items
heard, but the screen does not switch to the Warning display (white
with less than 0-hour
screen for resetting the remaining time. symbol displayed on red
remaining time for mainte-
background)
nance.
q You can lock the maintenance time by a pass-

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

q Enabling the password lock on an attachment-
equipped machine locks the breaker/attach-
ment setting screen at the same time.
a For information on changing the attachment/
maintenance password, see “Attachment/
maintenance password change function” in the
Testing and adjusting section.
User mode 1 F3 : Selects (highlights) an item one down.

q Pressing F6 on the normal screen enters the F4 : Selects (highlights) an item one up.
user mode, switching to the user menu screen. F5 : Cancels changes you made before confirming
q In user mode, you can specify items relating to them with F6 to return to the menu screen.
the machine monitor and machine shown F6 : Moves to the setup items of the selected (high-
below. lighted) item.
Breaker/attachment setting
Message display q Selecting B switches to the breaker setting
Screen adjustment menu, and selecting ATT switches to the
Time adjustment attachment setting menu.
Language setting q You can lock this menu with a password.
Economy mode adjustment Enabling the password lock locks the mainte-
nance reset screen at the same time.
F3 : Selects (highlights) an item one down.

F4 : Selects (highlights) an item one up.
F5 : Returns to the normal screen. Changing breaker mode setting
F6 : Switches to the setting screen for the selected q Selecting B on the breaker/attachment setting
item. screen switches to the breaker setting screen.
No operation at least 30 sec. : Returns to the nor- On this screen, select the breaker setting
mal screen. selection screen or breaker flow rate setting
(In user mode, no switch operation at least 30 sec. screen.
returns to the previous screen.)
Breaker/attachment setting
q For an attachment-equipped machine, this
menu allows you to adjust a flow rate in B
mode and ATT mode.
q For a machine with no attachment, this menu
does not appear.

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

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

q Selecting ATT on the breaker/attachment set-
F3 : Selects (highlights) an item one down. ting screen switches to the 2-way attachment
F4 : Selects (highlights) an item one up. setting menu. On this screen, select the
F5 : Returns to the breaker setting menu attachment setting screen or breaker flow rate
screen. setting screen.
F6 : Switches to the flow rate level setting
screen for the selected (highlighted) item.
F3 : Selects (highlights) an item one down. F3 : Selects (highlights) an item one down.
F4 : Selects (highlights) an item one up. F4 : Selects (highlights) an item one up.
F5 : Returns to the breaker/attachment setting F5 : Returns to the breaker setting menu
screen. screen.
F6 : Switches to the setting screen for the selected F6 : Switches to the flow rate level setting
(highlighted) item. screen for the selected (highlighted) item.
1. Attachment setting selection screen q On the flow rate level setting screen,
q On this screen, you can allocate one of change the set flow rate.
two set flow rates as a flow rate in attach-
ment mode.
q The ATT symbol is displayed before items
specified to attachment mode.
a The defaults of both flow rates are 550 l/
min.
F3 : Decreases the flow rate.

F4 : Increases the flow rate.
without changing the flow rate.
after specifying the flow rate.
F4 : Selects (highlights) an item one up. Flow level Flow (l/min) Remarks
F5 : Returns to the attachment setting menu.
8 550 Default
F6 : Specifies the selected (highlighted) item
as a flow rate in attachment mode. 7 476
q Selecting “No attachment” disables selec- 6 401
tion of attachment mode on the working 5 327
mode selection screen.
4 253
2. Attachment flow rate setting screen 3 179
q On this screen, you can specify a flow 2 104
rate. 1 30
q The ATT symbol is displayed before items
specified to attachment mode.
Message display
q For a KOMTRAX-equipped machine, you can
view notification from the sales representative.
When there is a message, the message moni-
tor appears on the upper left of the normal
screen.
q The lighting green monitor indicates that there
are messages to be read.
q The lighting blue monitor appears when you
have not sent replies yet after opening mes-
sages which accept replies.
q Messages will be deleted when their validity

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

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

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

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

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

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

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

Idle stop guidance function 1

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

the following conditions occurs.
q When the lever is operated
q When F5 is pressed
q When an error or caution occurs
When you switch to the normal screen by pressing
F5, this screen does not appear even if the engine
continues to run at idle. If the engine continues to
run at least five min. after operating the lever, this
screen appears again.
Service meter check function 1 Display LCD check function 1

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

goes out.
a Continuous operation of the machine monitor q Pressing any function switch returns to the pre-
may display blue bright spots on this screen; it vious screen.
is quite normal.
User code/failure code display function1

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

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

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

KOMTRAX communication modem, communi-
cation antenna, machine monitor, and GPS
antenna.
q This system transmits various kinds of
machine information wirelessly. Persons to
operate the KOMTRAX can refer to the infor-
mation at office to provide various kinds of ser-
vices for customers.
q Information transmittable from the KOMTRAX
terminal system includes the following.
1. Operation map
2. Service meter
3. Position information
4. Error history
and others.
a To provide the services, you need to make an
arrangement for starting the KOMTRAX ser-
vice separately.
KOMTRAX communication modem 1

TH300
1. Communication antenna connection Outline

2. Connector A (14 poles) q The KOMTRAX communication modem is a
3. Connector B (10 poles) wireless communication device to transmit var-
ious kinds of machine information or GPS posi-
tion information the monitor obtains from
network signals or input signals in the
machine. The communication modem can
transmit information via the communication
antenna.
q The modem is provided with a LED lamp as a
display unit. The LED is used for maintenance.
Input and output signals

Connector A Connector B
Input/ Input/
Pin No. Signal name Pin No. Signal name
output output
A-1 Electric power supply Input B-1 Serial signal DCD Output
A-2 NC(*1) — B-2 Serial signal RXD Output
A-3 NC(*1) — B-3 Serial signal TXD Input
A-4 Electric power supply switching Output B-4 Serial signal DTR Input
A-5 NC(*1) — B-5 Serial signal SGND Input
A-6 NC(*1) — B-6 Serial signal DSR Output
A-7 GND Input B-7 Serial signal RTS (*2) Input
A-8 GND Input B-8 Serial signal CTS (*2) Output
A-9 Modem power control 1 (*2) Input B-9 Serial signal RI (*2) Output
A-10 Modem power control 2 (*2) Input B-10 NC(*1) —
A-11 Modem serial control (*2) Input *1: Never connect to NC or malfunctions or failures
A-12 Electric field intensity 1 (*2) Output will occur.
A-13 Electric field intensity 2 (*2) Output *2: Signal used by TH200
A-14 NC(*1) —
*1: Never connect to NC or malfunctions or failures will
occur.
*2: Signal used by TH200
UEN02238-00

© 2007 KOMATSU
All Rights Reserved
70
UEN02643-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts ................................................................................................ 3
UEN02643-00 20 Standard value table
Standard value table for engine related parts 1

PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Engine SAA6D125E-5
Item Measurement conditions Unit Standard value Permissible value

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

Valve clearance
temperature Exhaust valve mm 0.71 —
Engine oil temperature: 40 – 60°C MPa
Compression pressure Min. 2.9 {Min. 30} 2.0 {200}
Engine speed: 200 – 250 rpm {kg/cm2}
kPa
At rated output Min. 0.98 {Min.
Blow-by pressure {mmH2O 1.96 {200}
Engine coolant temperature: Min. 70°C 100}
}
At rated output
Engine oil SAE0W30E0S, MPa 0.29 – 0.69
0.18 {1.8}
temperature: SAE5W40E0S, {kg/cm2} {3.0 – 7.0}
Min. 80°C SAE10W30DH,
Oil pressure
At low idle SAE15W40DH,
Engine oil SAE30DH MPa Min. 0.05
engine oil 0.03 {0.3}
temperature: {kg/cm2} {Min. 0.5}
Min. 80°C
Oil temperature All speed range (inside oil pan) °C 90 – 110 120
Fan belt, alternator belt Deflection when pressed with finger force
mm 13 – 16 13 – 16
tension of approx. 98 N {10 kg}
20 Standard value table UEN02643-00
Standard value table for chassis related parts 1

PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
gory
• Engine water 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 water temperature:
Engine speed

At 2-pump relief + one rpm
Within operating range 1,830 ± 100 1,830 ± 100
touch power up
• Arm relief + power max. switch
in ON condition
Speed when auto- • Auto-deceleration switch in ON
deceleration is oper- condition 1,300 ± 100 1,300 ± 100
ated • All control levers in NEUTRAL
condition
Boom control valve
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 centre 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 centre 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}
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
gory
Within operation range
4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Working mode: P mode
{42 ± 10} {42 ± 10}
• Hydraulic pump output pressure
with all control levers in NEU-
TRAL position
34.81 +1.47
–0.98 33.34 – 36.77
RAISE (37.27 +1.47
–0.98 ) (35.79 – 39.23)
{340 – 375 (365 – 400)}
{355 +15 +15
–10 (380 –10 )}
• Hydraulic oil
Boom temperature: At low-pres- 18.14 ± 0.98 16.67 – 19.61
sure setting {185 ± 10} {170 – 200}
LOWER
Within opera-
tion range At high-
31.38 ± 1.47 29.2 – 33.34
• Engine at high pressure
{320 ± 15} {300 – 340}
idle setting
• Working mode: P mode 34.81 +1.47 33.34 – 36.77
–0.98
• Hydraulic pump output pressure (35.79 – 39.23)
Arm
with all measurement circuits (37.27 +1.47
–0.98 ) {340 – 375
relieved {355 –10 (380 +15
+15
–10 )} (365 – 400)}
• Values inside parenthesis:
34.81 +1.47 33.34 – 36.77
Hydraulic oil pressure with –0.98
(35.79 – 39.23)
(37.27 +1.47
Hydraulic pressure
Bucket power max. switch in ON mode –0.98 ) {340 – 375

(reference only) {355 –10 (380 +15
+15
MPa –10 )} (365 – 400)}
{kg/ 30.89 +1.47
–2.45 27.95 – 32.85
Swing cm2}
{315 +15 {285 – 335}
–25 }
37.27 +2.94
–0.98 35.79 – 40.70
Travel
{380 +30 {365 – 415}
–10 }
Control circuit source • Engine at high idle 3.24 ± 0.2 2.84 – 3.43
pressure • Self pressure reducing valve {33 ± 2} {29 – 35}
output pressure with all control
levers in NEUTRAL position
• Hydraulic oil tem- When all
perature: Within control
4.2 ± 1.0 4.2 ± 1.0
operation range levers in
{42 ± 10} {42 ± 10}
• Engine at high idle NEUTRAL
• Working mode: P position
LS differential pressure
mode When trav-
• Travelling speed: Hi elling at half
• Hydraulic oil pump 2.65 ± 0.1 2.65 ± 0.1
stroke
pressure – LS {27 ± 1} {27 ± 1}
(without
pressure load)
PPC valve output Within operation range 2.9 +0.6
–0.2 2.9 +0.6
–0.2
pressure • Engine at high idle {30 +5.5 {30 +5.5
–1.5 } –1.5 }
• Control lever full stroke
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
gory
• Hydraulic oil temperature: deg.

Swing brake angle Max. 130 Max. 160
Within operating range (mm)
• Bucket: Empty
• Working mode: P mode
• Swing circle misalignment amount
when stopping after one turn
90° 3.7 ± 0.4 Max. 4.6

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

Hydraulic drift of swing operation range mm 0 0
• Engine stopped
• Keeping upper structure trans-
verse on slope of 15°
• Notching a mating mark on inner
and outer races of swing circle
• Mating mark misalignment amount
during 5 minutes
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
gory
operation range
Swing
Leakage from swing • Engine at high idle

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

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

operation range
• Engine at idle
Travel deviation mm Max. 200 Max. 300
• Travel speed: Lo
• Solid and flat ground
• Swerving amount while travelling
20 m (X) after initial 10 m trial run.
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
gory
Hydraulic drift of travel • Hydraulic oil temperature: mm 0 0

• Engine stopped
Travel
• Parking machine on slope 12° with

sprocket facing upslope
• Sliding distance for 5 minutes
Leakage of travel motor l/min Max. 20 Max. 40
• Travel: Lock sprocket.
• Oil leakage amount for one minute
with travelling in relief condition
Whole work
equipment (tooth Max. 700 Max. 1,050
tip fall amount)
Hydraulic drift of work equipment
Boom cylinder
(cylinder retrac- Max. 29 Max. 44
Work equipment
tion amount)
operation range
• Flat and level ground
Arm cylinder (cyl- • Work equipment in measurement mm
inder extension posture as illustrated above Max. 100 Max. 150
amount) • Bucket load: 3,060 kg
• Engine stopped
• Work equipment control lever in
NEUTRAL position
Bucket cylinder
• Fall amount for 15 minutes as
(cylinder retrac- Max. 35 Max. 53
measured every 5 minutes start-
tion amount)
ing immediately after initial set-
ting
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
RAISE
4.2 ± 0.4 Max. 5.0
Boom • Hydraulic oil temperature:

LOWER
• Time required from raise 2.8 ± 0.3 Max. 3.3
stroke end till bucket
touches ground
CURL
Work equipment speed
4.7 ± 0.5 Max. 5.4

Work equipment
Arm • Hydraulic oil temperature: sec.

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

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

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

• Time required from dump-
ing stroke end to digging
stroke end
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Boom sec. Max. 3.0 Max. 3.6

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

Time lag
Arm Max. 4.0 Max. 4.6

Work equipment

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

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

Internal leakage
Cylinders 4.5 20
cc/min
• Leakage amount for one
Centre swivel minute with cylinder or travel to
10 50
joint be measured in relief condition
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

Performance in compound operation

• Travelling speed: Lo
• Flat and level ground
Swerving amount in • Swerving amount (X) when
simultaneous opera- travelling 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
PC450-8, PC450LC-8
Applicable model
PC450LCHD-8
Cate- Permissible
Item Measurement Condition Unit Standard value
gory value
Discharge amount of hydraulic pump (P mode)

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

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

2
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point
of measurement, and use them as a base for calculating the pump discharge amount at the specified speed.
UEN02643-00

© 2007 KOMATSU
All Rights Reserved
12
UEN02644-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
30 Testing and adjusting 1

Testing and adjusting, part 1
Tools for testing, adjusting and troubleshooting.............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Measuring air boost pressure ......................................................................................................................... 8
Measuring exhaust temperature ..................................................................................................................... 9
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ..............................................................................................................................11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 15
Measuring engine oil pressure...................................................................................................................... 16
Handling fuel system parts............................................................................................................................ 17
Releasing residual pressure from fuel system .............................................................................................. 17
Measuring fuel pressure ............................................................................................................................... 18
Handling during cylinder cut-out operation ................................................................................................... 19
Handling during no injection cranking operation ........................................................................................... 19
Measuring fuel return rate and leakage ........................................................................................................ 20
Bleeding air from fuel circuit.......................................................................................................................... 23
UEN02644-00 30 Testing and adjusting
Checking fuel circuit for leakage ........................................................................................................ 24

Checking and adjusting fan belt and alternator belt ........................................................................... 25
Checking and adjusting air conditioner compressor belt tension ....................................................... 26
Measuring swing circle bearing clearance ......................................................................................... 27
Checking and adjusting track shoe tension........................................................................................ 28
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits ......................... 29
Measuring control circuit basic pressure ............................................................................................ 33
Checking and adjusting pump PC control circuit oil pressure ............................................................ 34
Checking and adjusting pump LS control circuit oil pressure............................................................. 37
Measuring solenoid valve output pressure......................................................................................... 42
Measuring PPC valve output pressure............................................................................................... 45
Adjusting play of work equipment and swing PPC valves.................................................................. 46
Inspecting locations of hydraulic drift of work equipment ................................................................... 47
Releasing residual pressure from hydraulic circuit............................................................................. 49
Measuring oil leakage amount ........................................................................................................... 50
Bleeding air from various parts........................................................................................................... 53
30 Testing and adjusting UEN02644-00
Tools for testing, adjusting and troubleshooting 1
Testing and adjusting Sym-

Part No. Part name Q'ty Remarks
item bol
–101 – 200 kPa {–760 – 1,500
Measuring intake air pres- 799-201-2202 Boost gauge kit 1
A mmHg}
sure (boost pressure)
799-401-2220 Hose 1
Measuring exhaust temper-
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ature
1 799-201-9001 Handy smoke checker 1
Measuring exhaust gas
C Commercially
color 2 Smoke meter 1
available
Commercially
Adjusting valve clearance D Clearance gauge 1 (Intake: 35 mm, Exhaust: 57 mm)
available
1 795-502-1590 Compression gauge 1 0 – 7.0 MPa {0 – 70 kg/cm2}
Measuring compression
E 795-471-1420 Adapter 1
pressure 2
6217-71-6112 Gasket 1
Measuring blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5.0 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 6.0, 40, 60
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Measuring engine oil pres- Pressure gauge: 60 MPa {600 kg/
G 790-261-1204 Digital hydraulic tester 1
sure cm2}
Pressure gauge: 1.0 MPa {10 kg/
2 799-401-2320 Gauge 1
cm2}
Pressure gauge: 2.5, 6.0, 40, 60
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600 kg/
790-261-1204 Digital hydraulic tester 1
cm2}
Measuring fuel pressure H
Pressure gauge: 1.0 MPa {10 kg/
2 799-401-2320 Gauge 1
cm2}
795-471-1450 Adapter 1 8 × 1.25 mm o R1/8
3
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint inside diameter: 10 mm
Commercially
3 Hose 1 Ø5 mm × 2 – 3 m
available
Measuring fuel return rate Commercially
J 4 Hose 1 Ø15 mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Measuring swing circle Commercially
K Dial gauge 1 With magnet
bearing clearance available
Measuring and adjusting oil 1 * Common with G1
pressure in work equipment, L
swing, and travel circuits 799-101-5220 Nipple 2
2 Size: 10 × 1.25 mm
07002-11023 O-ring 2

item bol
1 * Common with G1
Measuring and adjusting 790-261-1204 Digital hydraulic tester 1
M
control circuit voltage 799-101-5220 Nipple 2
2 * Common with K2
07002-11023 O-ring 2
Measuring and adjusting oil 1 * Common with G1
pressure in pump PC con- N
trol circuit 799-101-5220 Nipple 4
2
07002-11023 O-ring 4
1 * Common with G1
Measuring and adjusting oil
799-101-5220 Nipple 4
pressure in pump LS control O 2 * Common with M2
circuit 07002-11023 O-ring 4
Differential pressure
3 799-401-2701 1
gauge
1 * Common with G1
Measuring solenoid valve 799-401-3100 Adapter 1 Size: 02
P 2
output pressure 02896-11008 O-ring 1
799-401-3200 Adapter 1 Size: 03
3
02896-11009 O-ring 1
Measuring PPC valve out- 1 * Common with G1
Q 790-261-1204 Digital hydraulic tester 1
put pressure
2 799-301-1740 Joint 1 Size: PF1/4 + PT1/4
Commercially
Measuring oil leakage R Measuring cylinder 1
available
799-601-4100
or T-adapter assembly 1
799-601-4200
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
799-601-4180 • T-adapter 1 For EGR gas sensor
799-601-4211 • T-adapter 1 For controller (50-pole)
799-601-4220 • T-adapter 1 For controller (60-pole)
799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For Bkup sensor
Troubleshooting for/engine
S 799-601-4260 • T-adapter 1 For controller (4-pole)
controller/sensors/actuators
799-601-4330 • Socket 1 For Bkup sensor
799-601-4350 • T-box 1 For 60-pole type
For coolant temperature sensor
795-799-5530 • T-adapter 1
For fuel temperature sensor
795-799-5540 • T-adapter 1 For boost temperature sensor
For EGR valve solenoid
799-601-9020 • T-adapter 1 For bypass valve solenoid
For injector
For EGR valve solenoid
799-601-9030 • T-adapter 1
For bypass valve stroke sensor

item bol
799-601-9420 • T-adapter 1 For common rail pressure sensor
799-601-9430 • T-adapter 1 For supply pump PCV
799-601-9000
or
Troubleshooting for/engine
S 799-601-9100 T-adapter assembly 1
controller/sensors/actuators
or
799-601-9300
799-601-9310 • Plate 1
For 24-pole type
799-601-9320 • T-box 1
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter assembly 1
or
799-601-7100
or
799-601-7400
or
799-601-8000
799-601-2600 • T-adapter box 1
799-601-2740 • Adapter for MIC 1
799-601-4100
or
799-601-4200
799-601-9000
or
799-601-9200
Troubleshooting for chassis/ 799-601-9020 • Adapter for DT 1

T
sensors/wiring harnesses 799-601-9030 • Adapter for DT 1
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1
799-601-7020 • Adapter for X 1
799-601-7040 • Adapter for X 1
799-601-7050 • Adapter for SWP 1
799-601-7080 • Adapter for M 1
799-601-7090 • Adapter for M 1
799-601-7110 • Adapter for M 1
799-601-7120 • Adapter for M 1
799-601-7130 • Adapter for M 1
799-601-7140 • Adapter for S 1

item bol
799-601-7160 • Adapter for S 1
799-601-7170 • Adapter for S 1
799-601-7210 • Adapter for AMP040 1
799-601-7220 • Adapter for AMP040 1
799-601-7340 • Adapter for M 1
799-601-7360 • Adapter for relay 1
799-601-7370 • Adapter for relay 1
Troubleshooting for chassis/
T 799-601-7500 T-adapter assembly 1
sensors/wiring harnesses
799-601-7520 • Adapter for 070 1
799-601-9000
799-601-9200
799-601-9030 • Adapter for DT 1
799-601-9110 • Adapter for DT (GR) 1
799-601-9350 • Adapter for DRC 1
799-601-9360 • Adapter for DRC 1
Measuring wear on sprocket — 796-627-1120 Wear gauge 1
Measuring coolant tempera-
— 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
ture and oil temperature
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
—
and depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Ruler 1
hydraulic drift available
Measuring work equipment Commercially
— Stopwatch 1
speed available
Measuring voltage and Commercially
— Circuit tester 1
resistance available
a For the model names and part Nos. of the T-adapters and boxed used for troubleshooting for the
machine monitor, controllers, sensors, actuators and wiring harnesses, see “Troubleshooting, List of T-
boxes and T-adapters”.
Measuring engine speed 1 4) Measuring the engine speed when 2

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

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

tive conditions listed below.
1) RPM at low idle:
to the low idle (MIN) position.
2) RPM at high idle:
2] Set the working mode switch to P-
mode.
3] Turn off the auto-deceleration switch.
3) Measuring the engine speed when 2-
pumps are relieved:
2] Set the working mode switch to P-
mode.
3] Put the arm in the IN relief position.
Measuring air boost pressure 1 3. Run the engine at middle or higher speed and
drain oil from the hose.
a Air boost pressure measuring tools a When draining the oil, open the self seal of
Symbol Part No. Part name the hose by inserting approximately half of
the gauge and hose connection. Repeat
799-201-2202 Boost gauge kit
A operation until the oil is drained out.
799-401-2220 Hose a If Pm kit (A) is available, the air-bleeding
coupling (790-261-1130) in that kit may be
a Be careful not to touch any hot part of the used.
engine when removing or installing the mea- a If oil is left in the hose, the gauge does not
surement tools. work. Accordingly, be sure to drain the oil.
1. Open the inspection cover of the engine hood 4. Start the engine and keep it running until tem-
and remove intake air measuring plug (1). perature of the engine coolant and hydraulic oil
a The plug removed can be any of the plug rise to the operating range.
provided on the right and left side.
5. Set the working mode switch to P-mode.
6. Measure the intake air pressure (boost pres-

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

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

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

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

exhaust temperature measuring plug (1).

2. Install sensor [1] of digital thermometer B and
connect it to meter [2].
a Clamp the digital thermometer harness so
that it may not be accidentally contacted
against a hot part.

4. A procedure of measuring the maximum in

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

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

parts, while removing and installing a mea-
surement tool.
a If no compressed air or power is not available
in the field, use Handy Smoke Checker C1. For
recording official data, use Smoke Meter C2. 2) Connect the probe hose, accelerator switch
outlet and air hose to the smoke meter C2.
1. Measurement with Handy Smoke Checker C1 a Keep the pressure of the supplied com-
1) Fit a filtering paper to Handy Smoke pressed air at 1.5 MPa {15 kg/cm2} or
Checker C1. below.
2) Insert the exhaust gas intake port to 3) Connect the power cable to an AC receptacle.
exhaust pipe (1). a Confirm that the smoke meter power
3) Start the engine and keep it running until switch is in the OFF position, before
the engine coolant temperature rises to connecting the power cable to an outlet.
the operating range. 4) Loosen the cap nut of the suction pump
4) Start the engine and accelerate it sud- and fit in the filter paper.
denly or run it at high idle and then oper- a Fit the filtering paper securely so that
ate the lever of smoke checker C1 in order air may not leak.
to suction exhaust gas to the filter paper. 5) Move the Smoke Meter C2 power switch
to the ON position.
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Let the exhaust gas stay on the filtering
machine is back to normal condition. paper by depressing the accelerator pedal of
Smoke Meter C2, when the engine speed is
2. Measurement with Smoke Meter C2 suddenly accelerated or kept at high idle.
1) Insert probe [1] of smoke meter C2 to the 8) Put the polluted filtering paper on non-pol-
outlet of exhaust pipe (1) and fix it to the luted filtering paper (more than 10 sheets)
exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
Adjusting valve clearance 1

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

and remove the head cover (1) of every cylin-
der.
a As for No.1 and 2 cylinders, remove the
air intake connector on the head cover,
too.
5. When No. 1 cylinder is at the top dead center,
adjust valve clearances indicated with a black
bullet mark in the chart below in the following
manner.
2. Remove the belt protection covers (two cov-

ers) and then loosen the tension of the fan belt
and alternator belt.
a The belts are loosened for confirming the
timing mark. 6. Insert clearance gauge D in the clearance
between rocker arm (5) and crosshead (6) and
3. Remove radiator under cover. adjust the valve clearance with adjustment
screw (3).
4. Rotate the crankshaft forward to bring the a With the clearance gauge being inserted,
stamped “1.6TOP” line (a) of the damper to turn the adjustment screw until it allows
pointer (2) and set the No. 1 cylinder to the the clearance gauge to move slightly.
compression top dead center.
a Crank the crank shaft using the crank pul-
ley mounting bolt (Bolt width: 24 mm). In
this case, turn the bolt in the normal rota-
tion to prevent its loosening.
a When No. 1 cylinder is at the top dead
center, its rocker arm can be manually
moved as much as the valve clearance.If
it cannot be moved, that means that No. 1
cylinder is not yet at the top dead center.
In that case, rotate it by one more turn.
7. While fixing adjustment screw (3), tighten lock-

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

ders in the firing order by turning the crank
shaft 120° at a time.
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3 Air intake connector clamp:
9.8 ± 0.5 Nm {100 ± 5 kgm}
a Adjust the belt tension referencing “Test-
ing and adjusting fan belt and alternator
belt tension”.
Measuring compression pressure1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Compression pressure measurement tools (Do not pry the injector top up).
1 795-502-1590 Compression gauge
E 795-471-1420 Adapter
2
6217-71-6112 Gasket
k Be careful not to get burnt by touching the

exhaust manifold or muffler, or get caught
with a rotating parts, while taking measure-
ment of compression pressure.
a Before measuring the compression pressure,
make sure the engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Run the engine for warm up until the engine oil 5. Install adapter E2 to the injector mounting hole
reaches 40 – 60°C. and connect compression gauge E1 to it.
a Fit the gasket to the adapter end without
2. Open the inspection cover of the engine hood fail.
and remove the head cover (1) of the cylinder a Fix the adapter with the injector holder.
to be tested. 3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
6. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a See “Adjusting valve clearance”.
3. Bring the cylinder to be tested to the compres-

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

tor wiring harness (4) and remove injector (5).
a Before disconnecting the fuel high-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
7. Referencing “Special functions of machine 3 Rocker arm assembly mounting

monitor”, set the no injection cranking and the bolt:
engine speed measurement mode. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see “Adjusting valve clear-
set the engine in this mode. ance”.
8. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a Read the pressure gauge pointer when it
is stabilized.
9. After finishing testing, remove the testing tools

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

a Blow-by pressure measurement tools
.

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

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

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

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

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

and remove the bracket (2) for clamping.

2. Remove the oil pressure measurement plug

(1) on the cylinder block.
3. Install nipple [1] of hydraulic tester G1 and con-

nect it to hydraulic tester G2.
Handling fuel system parts 1 Releasing residual pressure from

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

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

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

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

tester H1 and connect them to hydraulic tester
H2.
Handling during cylinder cut-out Handling during no injection

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

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

fuel flowing out during the test.
2) Insert spacer J1 to return block (2) side
and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
3) Insert joint J2 to common rail (1) side and
retighten it with the currently removed joint
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect inspection hose J3 to the tip of

joint J2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the oil pan
while testing the return rate from the injec-
tor.
a Disconnect both ends of the injector.
1) Disconnect fuel return hose (4) of return
2. Testing leakage from pressure limiter block (2).
1) Adjust routing to prevent its slacking of a Place a plug on the fuel hose side
inspection hose J3 and insert the hose and then fix it to the fuel tank.
end to the oil pan (saucer). Plug: 07376-70315
2) Referencing “Measuring engine speed”,
set up the condition necessary for check-
ing the engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Engine speed Leakage
(rpm) (cc/min)
2) Connect inspection hose J4 to return
1,600 Max. 10 block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
3) Adjust routing to prevent its slacking of

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

After finishing all testing, remove the testing
4) Referencing “Measuring engine speed”, tools and return the removed parts.
set up the condition necessary for check-
ing the engine speed.
5) Run the engine at the rated output.
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
Bleeding air from fuel circuit 1

a If fuel is used up, or if a fuel circuit part is
removed or installed, bleed air from the fuel cir-
cuit according to the following procedure.
1. Loosen plug (2) at the top of fuel main filter (1)

to remove plug (3).
a Don't touch fuel pre-filter (4). It is situated
in the suction side.
2. Loosen lever-fixing butterfly screw (6) of prim-

ing pump (5) to remove it from the tap.
3. Repeat priming by pressing lever (7) of the

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

sure the fuel comes out of plug (1). Then
tighten plug (1).
5. Then conduct approximately 20 times of addi-

tional priming and install butterfly screw (6) of
priming pump.
3 Butterfly screw tightening torque:
11.7 Nm {1.2 kgm}
Checking fuel circuit for leakage 1 8. Run the engine at high idle and load it.
a When testing the engine mounted on the
k Very high pressure is generated in the high- machine, stall the torque converter or
pressure circuit of the fuel system. If fuel relieve the oil pressure from the hydraulic
leaks while the engine is running, it is dan- pump.
gerous since it can catch fire.
After testing the fuel system or removing 9. Inspect the fuel piping and devices for fuel
its parts, test it for fuel leakage according leakage.
to the following procedure. a Inspect mainly around the high-pressure
a Clean and degrease the engine and the parts circuit parts coated with the color checker
around it in advance so that you can test it eas- for fuel leakage.
ily for fuel leakage. a If any fuel leakage is detected, repair it
and inspect again from step 1.
1. Spray color checker (developer) over the fuel a If no fuel leakage is detected, inspection is
supply pump, common rail, fuel injector, and completed.
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

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

leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and check again from step 1.
4. Run the engine at low idle.

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

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

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

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

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

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

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

and travel circuits can be checked with moni-
toring function of the monitor panel, too (For
details, see “Special functions of monitor
panel”).
3) Start the engine and keep it running until
q Monitoring code: 01100 F pump pressure
the hydraulic oil pressure rises to the
01101 R pump pressure
operating range.
q Pump oil pressure is indicated in multiples of
1 MPa (1 kg/cm2, 1PSI).
Measuring
1. Preparation work
k Lower the work equipment to the
ground and, after stopping the engine,
release residual pressure in the piping
by operating the control lever several
times. Then loosen the oil filler cap
gradually to release pressure inside
the tank.
1) Open the pump room cover and remove
oil measuring plugs (1) and (2).
q (1): Front pump discharge pressure

measuring plug
q (2): Rear pump discharge pressure
measuring plug
2. Combination of pump, actuator, and valve a Turning on the swing lock switch
a When the oil from the pumps is divided, always turns on the 2-stage relief
the front pump and rear pump act inde- solenoid valve, causing the high-pres-
pendently on each actuator.Note that dif- sure relief. Accordingly, keep the
ferent actuators relieve different valves. swing lock switch turned OFF.
a When the work equipment circuit or swing
circuit is relieved singly, the oil of the 5. Measurement of swing relief pressure
pumps is diverted. 1) Start the engine and move the swing lock
a The actuators in the table are arranged in switch to the ON position.
the order when the control valve is seen 2) Measure hydraulic oil pressure when the
from the front of the machine. engine is running at high idle and the
swing circuit is relieved.
Pump Actuator Valve relieved
a Hydraulic oil pressure when the swing
(F unload valve) (F main relief valve) motor safety valve is relieved is dis-
Service Safety valve for service played.
Boom Hi a The relief pressure of the swing motor
F main relief valve is lower than the main relief pressure.
Arm Hi
Front
Bucket F main relief valve
6. Measurement of travel circuit relief pressure
Left travel F main relief valve 1) Start the engine, and lock the travel.
Raise: F main relief valve k Insert pin [2] between the sprocket
Boom
Lower: Safety-suction valve and the track frame to positively
(Pump merge-divider valve) (Travel junction valve) lock the travel circuit.
(Self pressure reducing valve)
Swing Swing motor safety valve
Rear Right travel R main relief valve
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Measurement of unload pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idle and all the
control levers are moved to the NEUTRAL
position. 2) Measure the pressure when the engine is
a Hydraulic oil pressure when the set to high idle and the travel circuit is
unload valve unloads is displayed. relieved.
a Hydraulic oil pressure with the main relief
4. Measurement of work equipment relief valve in relief condition is displayed. In
pressure the travel circuit relief, the pressure is
1) Start the engine and move the cylinder to high pressure relief all the time.
be measured to its stroke end. Adjusting
2) Measure hydraulic oil pressure when the a Adjustment of the unload valve is not available.
cylinder is relieved while the engine is run-
ning at high idle. 1. Adjustment of main relief pressure
a The pressure measured when the a When the relief pressure of the work
main relief valve is relieved is indi- equipment circuit or travel circuit is abnor-
cated. mal, adjust main relief valves (3) and (4)
a If the power maximizing switch is according to the following procedure.
released, the main relief valve is q (3): Front main relief valve
relieved at low pressure. If the former q (4): Rear main relief valve
is pressed, the latter is relieved at a When adjusting the main relief valve on
high pressure. the front pump side, remove the top cover
of the control valve.
a When adjusting the main relief valve on 2. Adjustment of boom LOWER relief pressure
the rear pump side, remove the under (on the side where high pressure is set)
cover of the control valve (when it is a If the high relief pressure for boom
installed). LOWER is not normal, adjust the high
a As for the main relief valve, be sure to pressure set side of safety-suction valve
adjust its low-pressure relief pressure (8) for boom LOWER according to the fol-
alone (adjusting the low-pressure relief lowing procedure.
pressure automatically sets the high-pres- a The the high-pressure relief pressure
sure relief pressure, too.). mode denotes the state in which the
a When the low-pressure relief pressure is machine push-up switch is turned on, dis-
turned on, the 2-stage relief valve is OFF abling to apply the pilot pressure to the
and thus the pilot pressure is not applica- switching port.
ble to the switching port.
1) Disconnect pilot hose (9).

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

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

6) Check the pressure again after the adjust- a If the swing relief pressure is abnormal,
ment, following the aforementioned steps adjust safety valve (14) of the swing motor
for measurement. according to the following procedure.
a Adjusting the high pressure set side
changes setting of the low pressure
side. Thus, this side requires adjust-
ment, too.
3. Adjustment of boom LOWER relief pressure

(on the side where low pressure is set)
a When the low relief pressure for boom
LOWER is not normal or when the high
pressure set side was adjusted, adjust the
low pressure side of safety-suction valve
(8) for boom LOWER according to the fol-
lowing procedure.
a The low-pressure relief pressure mode
denotes the state in which the machine
push-up switch is turned off, disabling to 1) While fixing adjusting screw (15), loosen
apply the pilot pressure to the switching port. locknut (16).
1) Disconnect pilot hose (9). 2) Turn adjustment screw (15) to adjust the
2) While fixing holder (12), loosen locknut pressure.
(13). a Adjustment screw:
3) Turn holder (10) to adjust the pressure. q Turning it clockwise increases
a Turning the holder clockwise increases the pressure.
the pressure. Turning it counterclock- q Turning it counterclockwise
wise decreases the pressure. decreases the pressure.
a Quantity of adjustment per turn of a Quantity of adjustment per turn of
holder: adjusting screw:
Approx. 25.3 MPa {Approx. 258 kg/cm2} 4.70 MPa {47.9kg/cm2}
4) While fixing holder (12), tighten locknut 3) While fixing adjustment screw (15), tighten
(13). locknut (16).
3 Locknut 78 – 93 Nm {8.0 – 9.5 kgm} 3 Locknut:
147 – 196 Nm {15 – 20 kgm}
5) Connect pilot hose (9).

6) Check the pressure again after the adjust- 4) Check the pressure again after the adjust-
ment, following the aforementioned steps ment, following the aforementioned steps
for measurement. for measurement.
Measuring control circuit basic 3. Start the engine and keep it running until the
pressure 1 hydraulic oil temperature rises to the operating
range.
a Control circuit oil pressure inspection and
adjustment tools 4. Measure hydraulic oil pressure, when the
Symbol Part No. Part name engine is running at high idle and all the control
levers are moved to the NEUTRAL position.
1
M
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
k Lower the work equipment to the ground
and, after stopping the engine, release
residual pressure in the piping by operating
the control lever several times. Then loosen
the oil filler cap gradually to release pres-
sure inside the tank.
1. Remove the top cover of the control valve and

remove plug (1) for measuring the control cir-
cuit basic pressure.
a The figure shows the control valve side
viewed from inside the pump room.
a It is not allowed to adjust the relief valve of
the control circuit source pressure.
2. Install nipple M2 and connect it to oil pressure

gauge [1] of hydraulic tester M1.
a Use the oil pressure gauge with capacity
6.0 MPa {60 kg/cm2}.
Checking and adjusting pump PC 2) Install nipple N2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauge with
a Pump PC control circuit oil pressure checking capacity 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
N
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
a Measurement of the oil pressure in the pump
PC control circuit shall be conducted after
making sure that oil pressure of the work
equipment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
q The figure shows the PC valve output
side.
1. Measurement of PC valve output pressure

(servo piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each
other.
oil pressure measuring plugs (1), (2), (3)
and (4).
measuring plug
measuring plug
the hydraulic oil temperature rises to the
q (3): Front PC valve output pressure
operating range.
measuring plug
q (4): Rear PC valve output pressure
measuring plug
4) Measure the pump discharge pressure 2) Install nipple N2 and connect it to oil pres-
and PC valve output pressure (pressure at sure gauge [1] of hydraulic tester N1.
servo piston inlet) at the same time after a The oil pressure gauges used shall
setting following conditions with the be 6.0 MPa {60 kg/cm2}.
engine running at high idle.
q Swing lock switch: ON
(Turning 2-stage relief ON induces
high-pressure relief)
q Work equipment, swing and travel:
Arm IN relief
a Method of judgment:
If the following ratio is obtained
between the pump discharge pres-
sure and PC valve output pressure
(servo piston output pressure), the
PC valve is normal.
Measured oil
Oil pressure ratio
pressure
Pump discharge the hydraulic oil temperature rises to the
1
pressure
operating range.
PC valve output Approx. 0.6
pressure (Approx. 3/5)
a If there is any abnormality with PC

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

PC-EPC valve output measuring plug (5). 4) Measure the hydraulic oil pressure with all
the control levers kept in the NEUTRAL
position and the engine running at high
idle and at low idle.
a You can assume that the PC-EPC
valve output pressure is normal when
the following changes are observed.
Control
Engine Oil pressure
lever
2.94 MPa
Low idle
{30 kg/cm2}
Neutral
0 MPa
High idle
{0 kg/cm2}

Adjusting 3. Tighten locknut (8).

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

PC valves (6) and (7) according to the proce-
dure shown below.
q As the working load increases, the engine
speed decreases remarkably.
q The engine speed is normal but the work
equipment speed is low.
q (6): Front pump PC valve
q (7): Rear pump PC valve
a The width across flats of the PC valve
locknut is 13 mm and that of the adjust-
ment screw (inside width) is 4 mm.Do not
turn any other locknuts or adjustment
screws since they affects the hydraulic
pump performance. 4. After the adjustment, make sure that the PC
valve output pressure (servo piston inlet pres-
sure) is normal using the measurement steps
explained earlier.
1. Loosen locknut (8).

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

terclockwise to adjust.
a Adjustment screw:
q Turn it clockwise when the work
equipment speed is low (to increase
pump absorption torque).
q Turn it counterclockwise when the
engine speed lowers (to decrease
pump absorption torque).
a Following indicates the range of adjust-
ment available from the adjusting screw.
q Counterclockwise: Within 1 turn
q Clockwise: Within 1 turn
Checking and adjusting pump LS 2) Install nipple O2 and connect it to oil pres-
control circuit oil pressure 1 sure gauge [1] of hydraulic tester O2.
a The oil pressure gauges used shall
a Pump LS control circuit oil pressure checking be 60 MPa {600 kg/cm2}.
and adjusting tools q The figure shows the pump discharge
Symbol Part No. Part name pressure side.
1
O 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
a Measurement of the oil pressure in the pump
LS control circuit shall be conducted after mak-
ing sure that oil pressure of the work equip-
ment, swing, and travel circuits as well as
basic pressure of the control circuit is normal.
and, after stopping the engine, release q The figure shows the LS valve output
residual pressure in the piping by operating side.
1. Measuring LS valve output pressure (servo

piston inlet pressure)
a PC valve output pressure (servo piston
inlet pressure) is measured along with that
of the pump discharge pressure and the
result of the two is compared to each other.
1) Remove oil pressure measuring plugs (1),
(2), (3) and (4).
measuring plug
measuring plug 3) Run the engine until the hydraulic oil tem-
q (3): Front pump LS valve output perature reaches the operating range and
pressure measuring plug then push up the measurement side track
q (4): Rear pump LS valve output pres- shoe with the work equipment.
sure measuring plug q When measuring the front circuit:
Left track shoe
q When measuring the rear circuit:
Right track shoe
k Provide a working area of suffi-
cient space, as the raised track
shoe will be idly rotated.
2. Measurement of LS differential pressure

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

and LS valve output pressure (pressure at
servo piston inlet) at the same time after
setting following conditions with the
engine running at high idle.
When all levers are at neutral and
when travel lever is at half stroke (one
side of travel is at idle)
a Let the raised track shoe idly rotate,
paying enough attention to the sur-
roundings for safety.
a Judgement method:
q (5): Front pump LS pressure measur-
When the ratio between the pump
ing plug
discharge pressure and LS valve out-
q (6): Rear pump LS pressure measur-
put pressure (servo piston output
ing plug
pressure) reaches the following val-
ues, both pressures are judged nor-
mal.
Oil pressure ratio
Measured oil Travel lever
pressure All levers
moved half-
at neutral
way
Pump discharge
Almost 1
pressure
same
LS valve output pressure Approx. 0.6

2) Install nipple O2 and connect it to the oil
pressure gauge of differential pressure
gauge O3 or hydraulic tester O1.
a When using differential pressure
gauge:
Connect the pump discharge pres-
sure to the high pressure side (back
side) and LS pressure to the low
pressure side (bottom side).
The differential pressure gaug e
needs 12 DCV power. Thus connect a
battery to it.
a When using the oil pressure gauge:

The oil pressure gauges used shall
be 60 MPa {600 kg/cm2}.
Differential pressure is approximately
2.9 MPa {30 kg/cm 2 } at maximum.
Thus measure the pressure recon-
necting the same gauge.
q The figure shows the pump discharge
pressure side.
4) Measure the pump discharge pressure and

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

slightly to the extent that the PPC oil
2) Install nipple O2 and connect it to oil pres- pressure switch is turned ON (Stop
sure gauge [1] of hydraulic tester O1. the operation short of starting the
a Use the oil pressure gauge with machine).
capacity 6.0 MPa {60 kg/cm2}. 5) Remove the measurement tool after the

operating range.
Adjusting
a If the LS differential pressure is abnormal,
adjust LS valves (8) and (9) according to the
q (8): Front pump LS valve
q (9): Rear pump LS valve
1. While fixing adjusting screw (10), loosen lock-

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

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

tial pressure is normal, following the steps for
measurement explained earlier.
Measuring solenoid valve output

pressure 1 2. Install adapter P2 or P3 and connect the cur-
rently disconnected hose again.
a Solenoid valve output pressure measurement
tools 3. Install nipple [1] of hydraulic tester P1 and con-
Symbol Part No. Part name nect it to oil pressure gauge [2].
a Use the oil pressure gauge with capacity
1 5.9 MPa {60 kg/cm2}.
790-261-1204 Digital hydraulic tester a Figure shows the outlet hose of the 2-
799-401-3100 Adapter (Size 02) stage solenoid valve being installed with
P 2 the measuring tool.
02896-11008 O-ring
799-401-3200 Adapter (Size 03)
3
02896-11009 O-ring
a Measure the solenoid valve output pressure

after confirming that the control circuit source
pressure is normal.
1. Remove the control valve top cover and dis- 4. Start the engine and keep it running until the
connect outlet hoses (1) to (7) of the target hydraulic oil temperature rises to the operating
solenoid valve of measurement. range.
a A quick coupler is attached to the solenoid
valve of PPC lock solenoid valve's outlet
hose. Thus, measurement shall be con-
ducted on PPC valve side (back side of
operator's cab).
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed shifting solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 PPC lock solenoid valve 5. Run the engine at high idle and operate the con-
trol levers and switches to turn the solenoid valve
ON or OFF. Measure the oil pressure when the
valve is turned on and also when turned off.
a For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing
“Table for functioning conditions” for each
solenoid valve.
a The operating condition of the solenoid
valve can be checked with the monitoring
function of the machine monitor (For the
operating procedure, see “Special func-
tions of machine monitor”.
a When each output pressure shows the fol-

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

Table for functioning conditions – 2-stage relief solenoid valve

Opera-
Operating condition
tion
Overheat 1st setting is ON
OFF
All of work equipment, swing, and travel signals are OFF
Swing lock switch is ON
Travel signal is ON
L-mode is selected ON
Boom LOWER signal is ON
Signals other than the swing single are ON
P or E-mode is selected Left knob switch is ON
Swing single is ON
OFF
Other than above conditions
Table for functioning conditions – machine push up solenoid valve

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

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

Opera-
Operating condition
tion
Overheat 2nd setting is ON
Fuel control dial is at 1,200 rpm or below
Travel speed switch is at Lo
OFF
Travel signal is OFF
F or R pump pressure is at 32.3 MPa {330 kg/cm2} or
Travel speed switch is at Mi or Hi above
Travel signal is ON
F or R pump pressure is at 18.6 MPa {190 kg/cm2} or
below ON
Table for functioning conditions – Merge/divide solenoid valve

Opera-
Operating condition
tion
When B mode is
Service single ON
selected
Travel is operated single ON
2
F or R pump pressure is at 19.6 MPa {200 kg/cm }
When a L-mode is not or above
Work equip- selected F or R pump pressure is at 14.7 MPa {150 kg/cm2}
Travel single signal ment, swing, OFF
or below
is ON and service
singles are F or R pump pressure is at 16.7 MPa {170 kg/cm2}
ON
ON or above
When L mode is selected
F or R pump pressure is at 11.8 MPa {120 kg/cm2}
OFF
or below
2
Arm IN and bucket CURL F or R pump pressure is at 24.5 MPa {250 kg/cm } ON
Travel signal is Swing sig- PPC pressure are or above
OFF nal is OFF 1.9 MPa {19.5 kg/cm2} or F or R pump pressure is at 19.6 MPa {200 kg/cm2}
above or below OFF
Table for functioning conditions – Travel junction solenoid valve

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

Opera-
Operating condition
tion
Lock OFF
Work equipment lock lever
Free ON
Measuring PPC valve output

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

sure inside the tank. 3. Connect nipple [1] of joint Q2 and hydraulic
tester Q1 and connect them to oil pressure
1. Remove the control valve top cover and the gauge [2].
operator cab under cover (front side). a Joint Q2 shall be used only when the mea-
surement is taken at the pressure sensor
2. Remove PPC hydraulic switch or PPC pres- installation position.
sure sensors (1) to (10) of the target circuit of a The oil pressure gauges used shall be 6.0
measurement. MPa {60 kg/cm2}.
a PPC pressure sensor for arm IN and a Figure shows the measuring tools being
bucket CURL detects errors in the electri- installed at the installation position of PPC
cal system as the starter switch is turned pressure sensor for arm IN circuit.
on when the connector is disconnected.
After removing the pressure sensor, con-
nect it to the connector again and then
clamp it to a nearby bracket.
Circuit to be mea- Circuit to be mea-
No. No.
sured sured
1 Boom RAISE (S06) 6 Bucket DUMP (S05)
2 Boom LOWER (S02) 7 Swing LEFT (S07)
3 Arm IN (S04) 8 Swing RIGHT (S03)
4 Arm OUT (S08) 9 Travel (S30)
5 Bucket CURL (S01) 10 Steering (S31)
4. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
5. Measure the pressure when the engine is run- Adjusting play of work equipment
ning at high idle and the control lever of the cir- and swing PPC valves 1
cuit to be measured is kept in the NEUTRAL
position and at the full stroke. a If there is excessive play in the work equip-
a If PPC valve output pressure is at the level ment or swing lever, adjust it in the following
shown below, it is judged normal. manner.
1. Remove work the equipment and swing PPC

Operation of levers Oil pressure
valve assembly.
Neutral 0 MPa {0 kg/cm2}
Almost the same pres- 2. Remove boot (1).
sure as the control cir-
Stroke end
cuit basic pressure (See 3. Loosen locknut (2) and push disc (3) into pis-
“Standard values table”) ton (4) until it touches the heads of 4 pistons
(4).
a Do not move the piston while doing this
6. Remove the measurement tool after the mea- work.
back to normal condition. 4. Keep disc (3) in place and tighten locknut (2) to
the specified tightening torque.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5. Install boot (1).
6. Install the work equipment and swing PPC

valve assembly.
Inspecting locations of hydraulic 2. Inspection of arm cylinder

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

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

position
q If the lowering speed is increased at
this time, the cylinder packing is
defective.
q If the lowering speed does not
change at this time, the control valve
is defective.
a Operate the control lever with the engine
starting switch in the ON position.
2) When inspecting the boom cylinder, shift a If pressure in the accumulator has
the boom control lever to RAISE side and dropped, run the engine for approx.
when inspecting the bucket cylinder, shift 10 seconds to charge the accumula-
the bucket control lever to CURL side. tor again.
q If, as the result, drifting speed
increases, failure on the cylinder [Reference] Reasons why the lowering
packing should be suspected. speed is increased by the above operation
q If the speed remains unchanged, fail- when the cylinder packing is the cause of
ure on the control valve should be the hydraulic drift:
suspected. 1) If the work equipment is set to the
a Operate the control lever with the above posture (holding pressure
engine starting switch in the ON posi- applied to the bottom end), the oil at
tion. the bottom end leaks to the head end.
a If pressure in the accumulator has However, the volume at the head end
dropped, run the engine for approx. is small than the volume at the bottom
10 seconds to charge the accumula- end by the volume of the rod end, so
tor again. the internal pressure at the head end
increases because of the oil flowing in
from the bottom end.
2) If the internal pressure of the head
end increases, the pressure at the
bottom end also rises in proportion to
this and balanced at certain level (this
level depends on the volume of leak-
age). As the pressure is balanced, the
drifting speed is decreased.
3) If the lever is then operated according

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

Measure the amount of hydraulic drift of the
work equipment when the accumulator is
charged with pressure and the lock lever is put
to the LOCK and FREE positions.
a Operate the control lever with the engine
starting switch in the ON position.
a If pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator again.
a If the lock and free position cause any dif-
ference in the hydraulic drift volume, the
PPC valve is defective (internal failure).
Releasing residual pressure from 3. Releasing residual pressure from swing

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

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

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

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

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

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

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

tion.
4) Run the engine at high idle, relieve the
swing circuit, and measure the oil leakage.
4) Run the engine at high idle, relieve the

travel circuit, and measure the oil leakage.
k Wrong operation of the lever can
cause an accident. Accordingly,
make signs and checks securely.
a Continue this condition for 30 sec-
onds, then measure the oil leakage
amount for one minute.
a Measure several times, moving the
motor a little (changing the position of
the valve plate and cylinder and that
of the cylinder and piston) each time.
Bleeding air from various parts 1

Air bleeding items Air bleeding procedure
1 2 3 4 5 6
Bleeding air Checking oil
Bleeding air Bleeding air Bleeding air
from Starting level and
from cylin- from swing from travel
hydraulic engine starting
der motor motor
Contents of work pump work
• Replacing hydraulic oil q q
q q q q
• Cleaning strainer (See note) (See note)
• Replacing return filter element q o o o q
• Replacing and repairing hydraulic
pump q q q o o q
• Removing suction piping
• Replacing and repairing control
valve q q o o q
• Removing control valve piping
• Replacing and repairing cylinder
q q o o q
• Removing cylinder piping
• Replacing and repairing swing
motor q o q o q
• Removing swing motor piping
• Replacing and repairing travel
motor q o o q q
• Removing travel motor piping
• Replacing and repairing swivel joint
q o o o q
• Removing swivel joint piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.
1. Bleeding air from hydraulic pump

1) Loosen air bleeder (1) to make sure oil
oozes out through the air bleeder.
2) When oil does not flow out, disconnect
drain hose (2) and then fill up the pump
case with oil fed from the drain port.
a Fix the drain hose mouthpiece in a
position higher than the oil level in the
hydraulic tank.
a Continue supplying oil to the pump
case until air is eliminated from the
flowing out oil.
3) After making sure that the oil from bleeder
(1) is free from mixed air, tighten the
bleeder.
3 Air bleeder:
2. Starting engine
When running the engine after performing step
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
1, keep its speed at low idle for 10 minutes.
a When the drain hose was discon-
a If the engine coolant temperature is low
nected for above operation, connect it
and the automatic warm-up operation is
again after tightening the bleeder.
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the fuel
control dial in the MAX position for 3 sec-
onds, and the automatic warm-up opera-
tion is reset).
3. Bleeding air from hydraulic cylinder 5. Bleeding air from travel motor
a In case a cylinder is replaced with new 1) Take off the travel motor cover.
one, it is advised to bleed air from the new 2) Start the engine and run it at low idle.
one before mounting the work equip- 3) Loosen bleeder (4) to make sure oil oozes
ment.It is especially so with the boom cyl- out.
inder, because its rod does not extend to 4) After making sure that the oil from bleeder
the stroke end of LOWER side, after the (4) is free from mixed air, tighten the
work equipment is mounted. bleeder.
1) Start the engine and keep running at low 3 Air bleeder:
idle for 5 minutes. 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
2) Raise and lower the boom 4 to 5 times
with the engine running at low idle.
a Stop the piston approximately 100
mm in front of the stroke end so that it
may not be relieved.
3) While running the engine at high idle, per-
form step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end and
relieve the oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor

1) Start the engine and run it at low idle.
5) Using the work equipment, lift the track
2) Loosen S port hose (3) gradually to make
shoe of one side.
sure oil oozes out through the S port hose.
k In this case, don't try to turn on the
6) Gradually run the lifted track shoe at idle
for approximately two minutes.
swing operation.
a Repeat the same for the opposite
3) When oil does not flow out, stop the
side track shoe.
engine once, disconnect S port hose and
then fill up the motor case with oil.
a As the motor case is filled up with oil,
connect S port hose once and then
repeat steps 1) and 2).
4) After making sure that the oil from S port
hose is free from mixed air, tighten the
hose.
5) Perform two times minimum of swing
operation in left and right directions at
slow speeds.
6. Checking oil level and refilling

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

the rear side of the hydraulic tank.
a The oil level is acceptable if it is situ-
ated between H and L lines.
a If the oil level is below line L, it is
insufficient. Add oil.
UEN02644-00

© 2007 KOMATSU
All Rights Reserved
56
UEN02645-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Testing and adjusting, Part 2
Special functions of machine monitor ............................................................................................................. 2
Special functions of machine monitor 1

Air conditioner specification
Heater specification Upper section of machine monitor (Display sec-

tion)
(a): Multi-display
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambi-
ent temperature and the condition of the bat-
tery. In this case, the machine monitor goes off
for a moment. This phenomenon is not a fail-
ure, however.
Upper section of machine monitor (Switch sec-

tion)
[F1]: F1 function switch
a The function of each function switch is indi-
cated by graphic mark in the multi-display (a)
above that function switch.
a If the graphic mark of a function switch is not
displayed, that function switch is not working.
Lower section of machine monitor (Switch sec-

tion)
[1]: Numeral 1 input switch/Auto-decelerator
switch
[2]: Numeral 2 input switch/Working mode selector
Heaterless specification switch
[3]: Numeral 3 input switch/Travel speed shifting
switch
[4]: Numeral 4 input switch/Alarm buzzer cancel
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Windshield washer
switch
[7]: Numeral 7 input switch/Air conditioner or
heater switch
heater switch
heater switch
heater switch
Switch having no numerals: Air conditioner or
heater switch
a Each switch has the function indicated by
graphic mark and the function of inputting a
numeral.
a The machine monitor automatically judges
which function of each switch is currently effec-
tive, according to the display condition of multi-
display.
a The difference between the air conditioner
specification, heater specification, and heater-
less specification is only the functions of the
switches in this section.
t Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary function and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the oth-
ers are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting.
Page Page
t Operator mode (Outline) Service mode
6p 20p
A Display of KOMATSU logo 6p Monitoring 21p
A Display of inputting password 7p Mechanical Systems 26p
Abnormality
A Display of check of breaker mode 7p Electrical Systems 27p
Record
A Display of check before starting 7p Air-conditioning System/Heater System 33p
A Display of warning after check before starting 8p Maintenance Record 34p
A Display of ending of maintenance interval 8p Maintenance Mode Change 35p
A Display of check of working mode and travel speed 8p Phone Number Entry 37p
A Display of ordinary screen 8p Key-on Mode 38p
A Display of end screen 9p Unit 39p
B Selection of auto-deceleration 9p With/Without Attachment 40p
O (Special operation)
B Selection of working mode 9p Default Attachment/Maintenance Password 41p

B Selection of travel speed 10p Camera 42p
B Operation to stop alarm buzzer 10p ECO Display 43p
B Operation of windshield wiper 11p Breaker Detect 44p
B Operation of window washer 11p Pump Absorption Torque (F) 45p
B Operation of air conditioner/heater 11p Pump Absorption Torque (R) 46p
Adjustment
Operation to display camera mode Low Speed 47p
B 12p
(if camera is installed)
Attachment Flow Adjustment 48p
B Operation to display clock and service meter 12p
Cylinder Cut-Out 49p
B Check of maintenance information 13p
No Injection 50p
Setting and display of user mode
B 13p Fuel Consumption 52p
(Including KOMTRAX messages for user)
C Display of energy-saving guidance 14p Terminal Status 53p
C Display of caution monitor 14p KOMTRAX GPS & Communication Status 54p
Settings MODEM S/N (TH300) 55p
C Display of automatic judgment of breaker 15p
C Display of user code and failure code 15p MODEM IP Address (TH200) 56p
O (Special operation) Display of KOMTRAX message 57p
Function of checking display of LCD

D 17p
(Liquid Crystal Display)
D Function of checking service meter 17p
Function of changing attachment/maintenance
D 18p
password
a Classification of operator mode

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

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

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

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

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

When the starting switch is turned OFF, the end Select a working mode according to the following
screen is displayed for 5 seconds. procedure.
a Another message may be displayed on the 1. While the ordinary screen is displayed, press
end screen, depending on the message dis- the working mode selector switch, and the
play function of KOMTRAX. working mode selection screen is displayed.
a The following figure is the working mode
selection screen displayed when "With
attachment" is set (If "With attachment" is
not set in the service mode, the attach-
ment mode [ATT] is not displayed).
Selection of auto-deceleration
While the ordinary screen is displayed, if the auto-
deceleration switch is pressed, large auto-deceler-
ation monitor (a) is displayed for 2 seconds and the
setting of the auto-deceleration is changed. 2. Operate the function switches or working mode
a Each time the auto-deceleration switch is selector switch to select and confirm the work-
pressed, the auto-deceleration is turned ON ing mode which you will use.
and OFF alternately. Function switches
a If the auto-deceleration is turned ON, large q [F3]: Move to lower working mode
monitor (a) and auto-deceleration monitor (b) q [F4]: Move to upper working mode
are displayed simultaneously. q [F5]: Cancel selection and return to ordi-
a If the auto-deceleration is turned OFF, auto- nary screen
deceleration monitor (b) goes off. q [F6]: Confirm selection and return to ordi-
nary screen
Working mode selector switch
q Press: Move to lower working mode
q Hold down:Confirm selection and return to
ordinary screen
a If you do not touch any of the function
switches and working mode selector
switch for 5 seconds, the selection is con-
firmed and the screen changes to the ordi-
nary screen.
3. When the ordinary screen is displayed again, Selection of travel speed

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

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

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

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

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

the caution monitor is displayed at the left
upper of the screen (The low hydraulic oil tem-
perature caution is not displayed there, how-
ever).
a When an error that there is a user code occurs
in the camera mode, if you do not touch any
control lever for 10 seconds, the screen
changes to the ordinary screen and displays
the error information.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is dis-
played on the right side. The image of camera
3 is displayed only singly.
a If the images of 2 cameras are displayed
simultaneously, images are displayed at inter-
vals of 1 second on the right and left screen.
Check of maintenance information Setting and display of user mode

While the maintenance monitor or ordinary screen (Including KOMTRAX messages for user)
is displayed, press [F5], and the maintenance table While the ordinary screen is displayed, press [F6],
screen is displayed. and the user menu screen is displayed.
a To reset the time left after finishing mainte- a There are following items in the user menu.
nance, more operations are necessary.
Breaker/Attachment Settings
User Message
Screen Adjustment
Clock Adjustment
Language
Economy Mode Adjustment
a The breaker/attachment setting menu is dis-

played only when "With attachment" is set in
the service mode.
[KOMTRAX message] Display of energy-saving guidance

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

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

the telephone mark is not displayed.
a Remedies given by displayed user codes to operator to take (The following table is an excerpt from the
Operation and Maintenance Manual)
User code Failure mode Action
When emergency pump drive switch is at the up (emergency)
E02 Pump control system error position, normal operations become possible, but have
inspection carried out immediately.
Move the swing brake cancel switch up to release the brake.
When applying the swing brake, operate the swing lock switch
E03 Swing brake system error manually. Depending on the cause of the problem, it may not
be possible to release it. In any case, have inspection carried
out immediately.
Engine controller power source error
E10 Engine controller drive system circuit error Have inspection carried out immediately.
(engine stopped)
Engine controller system error Operate machine to a safe posture and have inspection carried
E11
Output reduced to protect engine out immediately.
Operate machine to a safe posture and have inspection carried
E14 Abnormality in throttle system
out immediately.
Engine sensor (coolant temperature, fuel Operations are possible, but have inspection carried out
E15
pressure, oil pressure) system error immediately.
Operate machine to a safe posture and have inspection carried
E0E Network error
out immediately.
Function of checking display of LCD (Liquid Function of checking service meter

Crystal Display) To check the service meter while the starting switch
While the ordinary screen is displayed, if the follow- is turned OFF, operate the numeral input switches
ing numeral input switch and function switch are as follows. At this time, only the service meter sec-
operated as follows, all the LCD (Liquid Crystal Dis- tion displays.
play) lights up in white. q Operation of switches (simultaneous): [4] + [1]
q Operation of switches (simultaneous): [4] + [F2] a Since there is some time lag in start of the
a When finishing the operation of the switches, LCD, hold down the switches until the LCD dis-
release [F2] first. plays normally.
a If there is a display error in the LCD, only that a After the machine monitor is used continu-
part is indicated in black. ously, blue points (points which do not go off)
a The LCD panel sometimes has black points may be seen on this screen. This phenomenon
(points which are not lighted) and bright points does not indicate a failure or a defect.
(points which do not go off) for the reason of its
characteristics. If the number of the bright
points and black points does not exceed 10,
those points are not a failure or a defect.
a To return to the former screen, press the func-
tion switch.
Function of changing attachment/maintenance 3. After the New password input screen is dis-
password played, input a new password with the numeral
When changing the attachment/maintenance pass- input switches and confirm it with the function
word used for the attachment setting function and switch.
maintenance setting function, follow these proce- a Set a new password of 4 – 6 digits (If it
dures. has only 3 or less digits or has 7 or more
1. While the ordinary screen is displayed, perform digits, it is not accepted).
the following operation with the numeral input q [F5]: Reset input numeral/Return to ordi-
switches. nary screen
q Operation of switches (While pressing [4], q [F6]: Confirm input numeral
perform the operation in order):
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned on.
4. After the New password input screen is dis-

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

displayed and then the ordinary screen is dis-
played, the password is changed successfully.
t Service mode a The items which can be selected in the

To change the operator mode to the service mode, service menu are as follows (including
perform the following operation. some items which need special opera-
This operation is always required when you use the tions).
service mode. 01 Monitoring
Mechanical Systems
1. Check of display of screen and operation of
switches 02 Abnormality Electrical Systems
While the ordinary screen is displayed, perform Record
Air-conditioning System/Heater
the following operation with the numeral input System
switches. 03 Maintenance Record
q Operation of switches (While pressing [4],
04 Maintenance Mode Change
perform the operation in order):
[4] + [1] o [2] o [3] 05 Phone Number Entry
a This operation of the switches is accepted Key-on Mode
only while the ordinary screen is displayed. Unit
With/Without Attachment
Attachment/Maintenance
06 Default
Password
Camera
ECO Display
Breaker Detect
Pump Absorption Torque (F)
Pump Absorption Torque (R)
07 Adjustment
Low Speed
Attachment Flow Adjustment
08 Cylinder Cut-Out
09 No Injection
2. Selection of service menu
10 Fuel Consumption
When the Service menu screen is displayed,
the service mode is selected. Select a service Terminal Status
menu you use with the function switches or 11 KOMTRAX GPS & Communication Status
numeral input switches. Settings MODEM S/N (TH300)
q [F3]: Move to lower menu
MODEM IP Address (TH200)
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the
numeral input switches to select the menu
of that code and confirm it with [F6].
Monitoring
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed
to many parts of the machine and the information
from the controllers which are controlling switches,
etc.
1. Selecting menu
Select “Monitoring” on the service menu
screen.
3. Deciding monitoring items

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

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

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

Unit (Initial setting: ISO) Com-
Code ponent
Monitoring item (Display on screen) Remarks
No. ISO meter inch in
charge
00200 Controller Model Select — PUMP
00201 Machine ID — ENG
01002 Engine speed r/min rpm rpm ENG
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm2 psi PUMP
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket Dump PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC Pressure MPa kg/cm2 psi PUMP
04107 Coolant Temperature °C °C °F ENG
04401 Hydr. Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01302 PC-EPC Sol. Curr.(R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divider Sol. Curr.(Main) mA mA mA PUMP
08001 Merge-divider Sol. Curr.(LS) mA mA mA PUMP
01700 Service Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
03203 Battery Power Supply V V V ENG
04300 Battery Charge Vol. V V V MON
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18500 Charge Temperature °C °C °F ENG
Absolute value indication
36500 Boost Pressure kPa kg/cm2 psi ENG (including atmospheric
pressure)
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04200 Fuel Level Sensor Vol. V V V MON
04105 Eng. Water Temp. Vol. Lo V V V ENG
04402 Hydr. Temp. Sonser Vol. V V V PUMP
37401 Ambient Press Sens Volt V V V ENG
18501 Charge Temp Sens Volt V V V ENG
36501 Charge Press Sens Volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
17500 Engine Power Mode — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Press Command MPa kg/cm2 psi ENG
36300 Injection Timing Command CA CA CA ENG
37300 Fuel Rate l/h l/h gal/h ENG
01602 2nd Eng. Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP

Code ponent
charge
Swing ON•OFF PUMP
Travel ON•OFF PUMP
Boom Lower ON•OFF PUMP
01900 Pressure Switch 1
Boom Raise ON•OFF PUMP
Arm Curl ON•OFF PUMP
Arm Dump ON•OFF PUMP
Bucket Curl ON•OFF PUMP
Bucket Dump ON•OFF PUMP
01901 Pressure Switch 2
Service ON•OFF PUMP
Travel Steering ON•OFF PUMP
Travel Junction ON•OFF PUMP
Swing Brake ON•OFF PUMP
02300 Solenoid Valve 1 Merge-divider ON•OFF PUMP
2-Stage Relief ON•OFF PUMP
Travel Speed ON•OFF PUMP
02301 Solenoid Valve 2 Service Return ON•OFF PUMP
Lever Sw. ON•OFF PUMP
02200 Switch Input 1 Swing Release Sw. ON•OFF PUMP
Swing Brake Sw. ON•OFF PUMP
Model Select 1 ON•OFF PUMP
02201 Switch Input 2
Overload Alarm ON•OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON•OFF PUMP
Window Limit SW. ON•OFF PUMP
02204 Switch Input 5 P Limit SW. ON•OFF PUMP
W Limit SW. ON•OFF PUMP
Key Switch ON•OFF MON
Start ON•OFF MON
04500 Monitor input 1 Preheat ON•OFF MON
Light ON•OFF MON
Rad. Level ON•OFF MON
Air cleaner ON•OFF MON
04501 Monitor Input 2 Eng. Oil Level ON•OFF MON
Battery Charge ON•OFF MON
04502 Monitor Input 3 Swing Brake Sw. ON•OFF MON
F1 ON•OFF MON
F2 ON•OFF MON
Monitor Function F3 ON•OFF MON
04503
Switches F4 ON•OFF MON
F5 ON•OFF MON
F6 ON•OFF MON
SW1 ON•OFF MON
SW2 ON•OFF MON
Monitor 1st & 2nd SW3 ON•OFF MON
04504
Row Switches SW4 ON•OFF MON
SW5 ON•OFF MON
SW6 ON•OFF MON

Code ponent
charge
SW7 ON•OFF MON
SW8 ON•OFF MON
Monitor 3rd & 4th SW9 ON•OFF MON
04505
Row Switches SW10 ON•OFF MON
SW11 ON•OFF MON
SW12 ON•OFF MON
SW13 ON•OFF MON
Monitor 5th Row
04506 SW14 ON•OFF MON
Switches
SW15 ON•OFF MON
18800 Water In Fuel ON•OFF ENG WIF: Water In Fuel
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C °C °F ENG
20400 ECM Serial No — ENG
20227 Monitor Ass'y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog. P/N — MON
20229 Pump Con. Ass'y P/N — PUMP
20403 Pump Con. Serial No — PUMP
20230 Pump Con. Prog. P/N — PUMP
a Entry order of items in table

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

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

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

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

1) While the “Electrical Systems” screen is screen is displayed, operate the function
displayed, perform the following operation switches.
with the numeral input switches. q [F5]: Return to “Electrical systems”
q Operation of switches (While pressing screen (Reset mode)
[4], perform the operation in order): q [F6]: Execute reset
[4] + [1] o [2] o [3] a The following figure shows the screen
displayed when the items are reset
one by one (which is a little different
from the screen displayed when all
the items are reset together).
2) Check that the screen is set in the reset

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

User Alarm Component Category of
Failure code Trouble (Displayed on screen)
code buzzer in charge record
Electrical
989L00 Engine Controller Lock Caution 1 MON
system
Electrical
989M00 Engine Controller Lock Caution 2 MON
system
Electrical
989N00 Engine Controller Lock Caution 3 MON
system
Mechanical
AA10NX Air Cleaner Clogging MON
system
Mechanical
AB00KE Charge Voltage Low MON
system
Mechanical
B@BAZG Eng Oil Press. Low e ENG
system
Mechanical
B@BAZK Eng Oil Level Low MON
system
Mechanical
B@BCNS Eng Water Overheat e ENG
system
Mechanical
B@BCZK Eng Water Level Low e MON
system
Mechanical
B@HANS Hydr Oil Overheat e PUMP
system
Electrical
E10 CA111 EMC Critical Internal Failure q ENG
system
Electrical
E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG
system
Electrical
E11 CA122 Chg Air Press Sensor High Error q ENG
system
Electrical
E11 CA123 Chg Air Press Sensor Low Error q ENG
system
Electrical
E14 CA131 Throttle Sensor High Error q ENG
system
Electrical
E14 CA132 Throttle Sensor Low Error q ENG
system
Electrical
E15 CA144 Coolant Temp Sens High Error q ENG
system
Electrical
E15 CA145 Coolant Temp Sens Low Error q ENG
system
Electrical
E15 CA153 Chg Air Temp Sensor High Error q ENG
system
Electrical
E15 CA154 Chg Air Temp Sensor Low Error q ENG
system
Electrical
E11 CA155 Chg Air Temp High Speed Derate q ENG
system
Electrical
E15 CA187 Sens Supply 2 Volt Low Error q ENG
system
Electrical
E11 CA221 Ambient Press Sens High Error q ENG
system
Electrical
E11 CA222 Ambient Press Sens Low Error q ENG
system
Electrical
E15 CA227 Sens Supply 2 Volt High Error q ENG
system
Mechanical
CA234 Eng Overspeed ENG
system
Electrical
E15 CA238 Ne Speed Sens Supply Volt Error q ENG
system
Electrical
E10 CA271 IMV/PCV1 Short Error q ENG
system
Electrical
E10 CA272 IMV/PCV1 Open Error q ENG
system
Electrical
E11 CA322 Inj #1 (L#1) Open/Short Error q ENG
system

Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
E10 CA342 Calibration Code Incompatibility q ENG
system
Electrical
E10 CA351 Injectors Drive Circuit Error q ENG
system
Electrical
E15 CA352 Sens Supply 1 Volt Low Error q ENG
system
Electrical
E15 CA386 Sens Supply 1 Volt High Error q ENG
system
Electrical
E15 CA428 Water in Fuel Sensor High Error q ENG
system
Electrical
E15 CA429 Water in Fuel Sensor Low Error q ENG
system
Electrical
E15 CA435 Eng Oil Press Sw Error q ENG
system
Electrical
E10 CA441 Battery Voltage Low Error q ENG
system
Electrical
E10 CA442 Battery Voltage High Error q ENG
system
Electrical
E11 CA449 Rail Press Very High Error q ENG
system
Electrical
E11 CA451 Rail Press Sensor High Error q ENG
system
Electrical
E11 CA452 Rail Press Sensor Low Error q ENG
system
Electrical
E11 CA488 Chg Air Temp High Torque Derate q ENG
system
Electrical
E15 CA553 Rail Press High Error q ENG
system
Electrical
E15 CA559 Rail Press Low Error q ENG
system
Electrical
E15 CA689 Eng Ne Speed Sensor Error q ENG
system
Electrical
E15 CA731 Eng Bkup Speed Sens Phase Error q ENG
system
Electrical
E10 CA757 All Continuous Data Lost Error q ENG
system
Electrical
E15 CA778 Eng Bkup Speed Sensor Error q ENG
system
Electrical
E0E CA1633 KOMNET Datalink Timeout Error q ENG
system
Electrical
E14 CA2185 Throt Sens Sup Volt High Error q ENG
system
Electrical
E14 CA2186 Throt Sens Sup Volt Low Error q ENG
system
Electrical
E11 CA2249 Rail Press Very Low Error q ENG
system
Electrical
E11 CA2311 IMV Solenoid Error q ENG
system
Electrical
E15 CA2555 Grid Htr Relay Volt High Error q ENG
system

Electrical
E15 CA2556 Grid Htr Relay Volt Low Error q ENG
system
Electrical
E01 D19JKZ Personal Code Relay Abnormality q MON2
system
Electrical
D862KA GPS Antenna Discon MON2
system
Electrical
E0E DA22KK Pump Solenoid Power Low Error q PUMP
system
Electrical
DA25KP 5 V Sensor 1 Power Abnormality PUMP
system
Electrical
DA29KQ Model Selection Abnormality PUMP
system
Electrical
E0E DA2RMC CAN Discon (Pump Con Detected) q PUMP
system
Electrical
DAFGMC GPS Module Error MON2
system
Electrical
E0E DAFRMC CAN Discon (Monitor Detected) q MON
system
Electrical
DGH2KB Hydr Oil Sensor Short PUMP
system
Electrical
DHPAMA F Pump Press Sensor Abnormality PUMP
system
Electrical
DHPBMA R Pump Press Sensor Abnormality PUMP
system
Electrical
DHS3MA Arm Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS4MA Bucket Curl PPC Press Sensor Abnormality PUMP
system
Electrical
DHS8MA Boom Raise PPC Press Sensor Abnormality PUMP
system
Electrical
DHSAMA Swing RH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSBMA Swing LH PPC Press Sensor Abnormality PUMP
system
Electrical
DHSDMA Bucket Dump PPC Press Sensor Abnormality PUMP
system
Electrical
DHX1MA Overload Sensor Abnormality (Analog) PUMP
system
Electrical
DW43KA Travel Speed Sol Discon PUMP
system
Electrical
DW43KB Travel Speed Sol Short PUMP
system
Electrical
E03 DW45KA Swing Brake Sol Discon q PUMP
system
Electrical
E03 DW45KB Swing Brake Sol Short q PUMP
system
Electrical
DW91KA Travel Junction Sol Discon PUMP
system
Electrical
DW91KB Travel Junction Sol Short PUMP
system
Electrical
DWA2KA Service Sol Discon PUMP
system
Electrical
DWA2KB Service Sol Short PUMP
system
Electrical
DWK0KA 2-stage Relief Sol Discon PUMP
system
Electrical
DWK0KB 2-stage Relief Sol Short PUMP
system
Electrical
E02 DXA8KA PC-EPC (F) Sol Discon q PUMP
system

Electrical
E02 DXA8KB PC-EPC (F) Sol Short q PUMP
system
Electrical
E02 DXA9KA PC-EPC (R) Sol Discon q PUMP
system
Electrical
E02 DXA9KB PC-EPC (R) Sol Short q PUMP
system
Electrical
DXE0KA LS-EPC Sol Discon PUMP
system
Electrical
DXE0KB LS-EPC Sol Short PUMP
system
Electrical
DXE4KA Service Current EPC Discon PUMP
system
Electrical
DXE4KB Service Current EPC Short PUMP
system
Electrical
DXE5KA Merge-divider Main Sol Discon PUMP
system
Electrical
DXE5KB Merge-divider Main Sol Short PUMP
system
Electrical
DXE6KA Merge-divider LS Sol Discon PUMP
system
Electrical
DXE6KB Merge-divider LS Sol Short PUMP
system
Electrical
DY20KA Wiper Working Abnormality PUMP
system
Electrical
DY20MA Wiper Parking Abnormality PUMP
system
Electrical
DY2CKA Washer Drive Discon PUMP
system
Electrical
DY2CKB Washer Drive Short PUMP
system
Electrical
DY2DKB Wiper Drive (For) Short PUMP
system
Electrical
DY2EKB Wiper Drive (Rev) Short PUMP
system
a Entry order of items in table

The items are entered in the order of their failure codes (incremental order).
a User code
Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis-
tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Not attached: Even if the failure code is detected, the machine monitor does not notify the operator of
the abnormality.
a Alarm buzzer
q : When occurrence of an error is notified to the operator, the buzzer sounds (The operator can stop
the buzzer with the alarm buzzer cancel switch).
e: Since the caution monitor is also turned ON, its function sounds the buzzer.
a Component in charge
MON: The machine monitor is in charge of detection of abnormality.
MON2: The KOMTRAX section of the machine monitor is in charge of detection of abnormality.
ENG: The engine controller is in charge of detection of abnormality.
PUMP: The pump controller is in charge of detection of abnormality.
a Category of record
Mechanical system: Abnormality information is recorded in the mechanical system abnormality record.
Electrical system: Abnormality information is recorded in the electrical system abnormality record.
Abnormality Record (Air-conditioning System/ 3. Information displayed on “abnormality record”

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

After the “Abnormality Record” screen is dis-
played, select “Air-conditioning System” or 4. Resetting abnormality record
“Heater System” with the function switches or While the “abnormality record” screen is dis-
numeral input switches. played, press [F2], and the number of occur-
q [F3]: Move to lower item rence time of abnormality is reset. If it is
q [F4]: Move to upper item confirmed at this time that the abnormality has
q [F5]: Return to service menu screen been reset, the display changes to Normal.
a You may enter a 2-digit code with the a Heater specification
numeral input switches to select the In the heater specification, the display of “Air-
record of that code and confirm it with conditioning” is replaced with “Heater” and the
[F6]. items which are not related to the heater are
not displayed.
a Heaterless specification
In the heaterless specification, the abnormality
record menu and screen are not displayed.
Maintenance Record a The following items can be selected in the

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

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

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

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

off
After selecting “Maintenance Mode On/Off”, if
the screen is displayed, set ON or OFF with
the function switches.
q ON: Functions of all maintenance items
are set effective in operator mode
2. Selecting sub menu q OFF: Functions of all maintenance items
After the “Maintenance Mode Change” screen are set ineffective in operator mode
is displayed, select an item to change the set- q [F3]: Move to lower item
ting with the function switches or numeral input q [F4]: Move to upper item
switches. q [F5]: Cancel selection and return to Main-
q [F1]: Move to next page (screen) tenance mode change screen
q [F2]: Move to previous page (screen) q [F6]: Confirm selection and return to
q [F3]: Move to lower item Maintenance mode change screen
q [F4]: Move to upper item a Even if ON/OFF of each item has been
q [F5]: Return to service menu screen set, if the above setting is changed, it is
a You may enter a 2-digit code with the applied.
numeral input switches to select the item
4. Contents of setting of each maintenance item 5. Function of initializing all items

After selecting each maintenance item, if the After selecting “All Default Value”, if the screen
screen is displayed, set the item with the func- is displayed, set with the function switches.
tion switches. q If this operation is executed, the set val-
q Initial value: Maintenance interval set in ues of all the maintenance items are ini-
machine monitor (Recommended by man- tialized.
ufacturer and not changeable). q [F5]: Return to Maintenance mode change
q Set value: Maintenance interval which can screen
be set freely. Maintenance functions in q [F6]: Execute initialization
operator mode operate on basis of this set a A while after [F6] is pressed, the initializa-
time (which is increased or decreased by tion completion screen is displayed. Then,
50 hours). if the “Maintenance Mode Change” screen
q ON: Maintenance function of this item is is displayed, initialization is completed.
set effective in operator mode.
q OFF: Maintenance function of this item is
set ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or
OFF (Lower).
q [F4]: Select Increase set value (Upper) or
ON (Lower).
q [F5]: Cancel setting before confirmation
and return to Maintenance mode
change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower
lines is confirmed with [F6] and the screen
changes to the Maintenance mode
change screen with [F5], the setting is
effective.
a If the set value of an item set to “ON” is
changed after 1 or more operating hours
since the start of setting, the change is
recognized as a resetting operation.
Phone Number Entry a If [F6] is pressed without inputting a digit,

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

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

Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (orange background) and over-
write it with the correct digit.
Default (Key-on Mode) q Mode at Previous Key-off: Final mode in

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

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

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

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

Check or change various settings related to the setting is not carried out normally, the
machine monitor and machine by "Default". attachment cannot be set in the operator
The "With/Without attachment" function is used to mode. As a result, the attachment may not
set an installed or a remove attachment. work normally or the hydraulic compo-
nents may have trouble.
1. Selecting menu
Select "Default" on the “Service Menu” screen.

After the "Default" screen is displayed, select
“With/Without Attachment” with the function
switches or numeral input switches.
3. Selecting With/Without
After the “With/Without Attachment” screen is
displayed, select the setting with the function
switches.
q Without Attachment:
When attachment is not installed
q With Attachment:
When attachment is installed
q [F3] : Move to lower item
q [F4] : Move to upper item
q [F5] : Cancel selection and return to
Default screen
q [F6] : Confirm selection and return to
Default screen
Default (Attachment/Maintenance Password) 3. Selecting Disable/Enable

Check or change various settings related to the After the Attachment/Maintenance Password
machine monitor and machine by "Default". screen is displayed, select the setting with the
The function of setting attachment/maintenance function switches.
password is used to set the display of the password q Disable : Password screen is not dis-
screen when the functions related to the attach- played
ment and maintenance are used in the operator q Enable : Password screen is displayed
mode. q [F3] : Move to lower item
q [F4] : Move to upper item
1. Selecting menu q [F5] : Cancel selection and return to
Select “Default” on the “Service Menu” screen. "Default" screen
q [F6] : Confirm selection and return to
"Default" screen

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

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

Check or change various settings related to the After the “Camera” setting screen is displayed,
machine monitor and machine by "Default". select the setting with the function switches.
The camera setting function is used to set installa- q OFF: Camera is not used
tion and removal of a camera. q Original Image: Image of connected cam-
era is displayed in origi-
1. Selecting menu nal position (as in mirror,
Select “Default” on the “Service Menu” screen. used as back monitor)
q Reverse Image: Image of connected cam-
era is displayed in reverse
position (as seen directly,
used as front or side mon-
itor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation
and return to “Default” screen
q [F6]: Confirm selection in each line
a After “Camera” screen is displayed, cam-
era 1 can be always set. When 2 or more
cameras are connected, if camera 1 is set,
the screen changes to setting of camera 2
automatically.
2. Selecting sub menu a After confirming the setting of each line
After the “Default” screen is displayed, select with [F6], return to the "Default" screen
“Camera” with the function switches or with [F5], and the setting is effective.
numeral input switches. a If a camera is connected but not set nor-
a Select this item similarly to an item on the mally with this function, the graphic mark
“Service Menu” Screen. of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of
the camera cannot be used.
a If 2 or more cameras are connected, be
sure to set the use of them from camera 1
in order.
a The function of displaying 2 images simul-
taneously is effective when use of camera
1 and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizon-
tally.
Default (ECO Display) a If ECO display is turned ON, ECO is dis-

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

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

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

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

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

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

After the “Adjustment” screen is displayed,
select “Pump Absorption Torque (F)” with the
function switches or numeral input switches. a Relationship between set value and
a Select this item similarly to an item on the torque adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
Adjustment (Pump Absorption Torque (R)) 3. Selecting absorption torque

The operator can adjust various items related to the After the "Pump Absorption Torque (R)" screen
machine with the machine monitor. is displayed, select a set value on the right side
The pump absorption torque (R) function is used to with the function switches.
finely adjust the absorption torque on the rear side q Set value: For actual torque adjustment
of the hydraulic pump. value, see table
q [F3]: Increase set value
1. Selecting menu q [F4]: Decrease set value
Select “Adjustment” on the “Service Menu” screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen

select “Pump Absorption Torque (R)” with the
function switches or numeral input switches. a Relationship between set value and torque
a Select this item similarly to an item on the adjustment value
“Service Menu” screen. Set
Code Torque adjustment value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 –9.8 Nm {–1 kgm}
006 –19.6 Nm {–2 kgm}
007 –29.4 Nm {–3 kgm}
008 –39.2 Nm {–4 kgm}
Adjustment (Low speed) 3. Selecting travel Low speed

The operator can adjust various items related to the After the "Low Speed" setting screen is dis-
machine with the machine monitor. played, select a set value on the right side with
The travel Low speed setting function is used to the function switches.
finely adjust the travel Low speed. q Set value: For actual travel Low speed
value, see table
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” screen. q [F4]: Decrease set value
q [F6]: Confirm setting and return to Adjust-
ment menu screen

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

The operator can adjust various items related to the After the screen of "Attachment Flow Adjust-
machine with the machine monitor. ment" is displayed, select a set value on the
The function of "Attachment Flow Adjustment" is right side with the function switches.
used to finely adjust the oil flow to the attachment in q Set value: For actual distribution of flow,
compound operation. see table
1. Selecting menu q [F3]: Increase set value
Select “Adjustment” on the “Service Menu” q [F4]: Decrease set value
screen. q [F6]: Confirm setting and return to Adjust-
ment menu screen

select “Attachment Flow Adjustment” with the
function switches or numeral input switches. a Relationship between set value and distri-
a Select this item similarly to an item on the bution of flow to attachment
“Service Menu” screen. Set Distribution of flow to
Code
value attachment
000 50 %
001 70 %
044
002 100 %
003 40 %
Cylinder Cut-Out
The operator can perform "Cylinder Cut-Out" oper-
ation with the machine monitor.
"Cylinder Cut-Out" operation means to run the
engine with 1 or more fuel injectors disabled electri-
cally to reduce the number of effective cylinders.
This operation is used to find out a cylinder which
does not output power normally (combustion in it is
abnormal).
1. Selecting menu
Select “Cylinder Cut-Out” on the “Service
Menu” screen.
3. Resetting Cut-Out cylinder

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

If the "No injection" screen is displayed, the
machine monitor asks the operator if no injec-
tion cranking should be performed. Answer
with the function switch.
q [F5]: Do not perform (Return to Service
menu screen)
q [F6]: Perform
a While the screen is changing to the follow-
ing screen, the screen of "Communication
between controllers is being checked" is
displayed.
3. Starting no injection cranking 5. Prohibiting no injection cranking

If no injection cranking (Fuel injection in no cyl- If the operator tries to perform the no injection
inders) becomes effective, that is displayed on cranking while the engine is running, the mes-
the screen. Under this condition, crank the sage that the engine is running is displayed
engine with the starting motor. and the no injection cranking is not set effec-
a While the screen is changing to the follow- tive.
ing screen, the screen of "Setting is being a This function can be selected even while
prepared" is displayed. the engine is running. If the no injection
a Limit the cranking time to 20 seconds to cranking is performed, however, the mes-
protect the starting motor. sage of "Engine is running" is displayed
on the screen.
4. Finishing no injection cranking

After completing the no injection cranking
operation, press [F6], and finish of no injection
cranking is displayed and the screen returns to
the “Service Menu” screen automatically.
Fuel Consumption 3. Display and function during measurement

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

according to the unit set with the default
(unit setting) function.
SI and meter: l/h
inch: gal/h
KOMTRAX Settings (Terminal Status) 3. Contents of display of terminal status

The setting condition and operating condition of On the “Terminal Status” screen, the following
KOM TRAX c an b e c he c k e d wi t h Display of items are displayed.
KOMTRAX setting. q Terminal type: Model name of KOMTRAX
Setting condition of terminal is used to check the communication MODEM
setting condition of the KOMTRAX terminal. q KOMTRAX communication: Executing con-
dition of station opening inspection
1. Selecting menu q GMT time: Greenwich Meant Time
Select “KOMTRAX Settings” on the “Service q [F5]: Return to KOMTRAX settings screen
Menu” screen.

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

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

The setting condition and operating condition of The serial No. of TH300 Modem is displayed.
KOM TRAX c an b e c he c k e d wi t h Display of q [F5]: Return to KOMTRAX settings screen
KOMTRAX setting.
MODEM S/N is used to check the serial No. of the
KOMTRAX communication MODEM.
1. Selecting menu
Select “KOMTRAX Settings” on the “Service
Menu” screen.

played, select “Modem S/N” with the function
KOMTRAX Settings (IP Address: TH200) 3. Contents of display of IP address

The setting condition and operating condition of The telephone No. and IP address (2 systems)
KO M TRAX c an b e c h ec ke d w ith Dis pla y of of TH200 MODEM are displayed.
KOMTRAX settings. q [F5]: Return to KOMTRAX setting screen
IP address is used to check the IP address of the a The IP address is a No. specific to each
KOMTRAX communication MODEM. MODEM which is required when commu-
nication is made between the MODEM
1. Selecting menu and the server.
Select "KOMTRAX Settings" on the service
menu screen.

played, select “IP Address” with the function
Display of KOMTRAX message 3. Display of message (with return mail function)

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

If there is a message, its contents are dis-
played. If there is not a message, "No mes-
sage" is displayed.
a This message is different from a message
transmitted to the operator in the operator
mode.
a Since this message is special for the ser-
viceman, the message monitor is not dis-
played when it is received as in the
operator mode.
UEN02645-00

© 2007 KOMATSU
All Rights Reserved
58
UEN02662-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Testing and adjusting, Part 3
Handling voltage circuit of engine controller ................................................................................................... 2
Preparation work for troubleshooting of electrical system .............................................................................. 3
Procedure for testing diodes ........................................................................................................................... 8
Pm Clinic service ............................................................................................................................................ 9
Handling voltage circuit of engine

controller 1
1. Before disconnecting or connecting a connec-
tor between the engine controller and engine,
be sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
Preparation work for 4) Insert or connect troubleshooting T-adapt-

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

3) Remove 1 mounting bolt and duct (3). ers in or to connectors ENG, CE02, and
CE03 of engine controller (2).
a Connectors are fixed with screw.
Loosen the screws before discon-
necting them.
a When returning the connectors back
to their position, tighten them to the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
7) Connect the troubleshooting adapters to

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

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

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

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

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

a Disconnection and connection of con-
nector
The connector of the supply pump IMV
solenoid has a special locking mecha-
nism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection: (a) Unlock – (b) Discon-
nect connector.
Connection: (c) Connect connector – (d)
Lock.
8. Common rail pressure sensor (FUEL RAIL 9. Engine coolant temperature sensor (COOL-
PRESS) ANT TEMP)
a Disconnection and connection of con- a Disconnection and connection of con-
nector nector
The connector of the common rail pres- The connector of the engine coolant tem-
sure sensor has a special locking mecha- perature sensor has a special locking
nism. Disconnect it according to steps (a) mechanism. Disconnect it according to
– (b) and connect it according to steps (c) steps (a) – (b) and connect it according to
– (d) as shown below. steps (c) – (d) as shown below.
Disconnection: (a) Unlock – (b) Discon- Disconnection: (a) Unlock – (b) Discon-
nect connector. nect connector.
Connection: (c) Connect connector – (d) Connection: (c) Connect connector – (d)
Lock. Lock.
a Removal and installation of sensor

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

a Test the assembled-type diode (8-pin) and the
single diode (2-pin) according to the following
procedure.
a The conductive directions of the assembled-
type diode are as follows.
2. When using analog circuit tester

1) Set the tester in the resistance range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
i) Apply the red (+) lead of the tester to
the anode (P) side of the diode and
a The conductive direction of the single diode is apply the black (–) lead to the cath-
indicated on the surface of the diode. ode (N) side.
ii) Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Judge the condition of the diode by the
movement of the pointer.
q The pointer does not move in i) but
moves in ii): The diode is normal (The
moving range (resistance) depends
on the type and selected range of the
tester, however).
q The pointer moves in both i) and ii):
The diode is defective (Internal short
circuit).
1. When using digital circuit tester q The pointer moves in neither of i) and
1) Set the tester in the diode range and ii): The diode is defective (Internal
check the indicated value. disconnection).
a When an ordinary circuit tester is
used, the voltage of the internal bat-
tery is indicated.
2) Apply the red (+) lead of the tester to the
anode (P) side of the diode and apply the
black (–) lead to the cathode (N) side and
check the indicated value.
3) Judge the condition of the diode by the
indicated value.
q The indicated value does not change:
The diode does not have conductivity
(Defective).
q The indicated value changes:
The diode has conductivity (Normal).
Note: In the case of a silicon diode, a
value in the range from 460 to 600 is indi-
cated.
Pm Clinic service 1
Model name Serial No. Service meter
T PC400-8
h
T PC450-8 T LC
User's name Date of execution Inspector
/ /
Specifications
Main components Attachments Shoe width
Boom T Standard T ( ) T Breaker T 600 mm T 800 mm
Arm T Standard T ( ) T( ) T 700 mm
Bucket T Standard T ( ) T( ) T( )
Check of oil/coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's opinion
Result of visual inspection
Mechanical equipment system fault history Electrical equipment system fault history
AA10NX times/1st time h/last h times/1st time h/last h
AB00KE times/1st time h/last h times/1st time h/last h
B@BAZG times/1st time h/last h times/1st time h/last h
B@BAZK times/1st time h/last h times/1st time h/last h
B@BCNS times/1st time h/last h times/1st time h/last h
B@BCZK times/1st time h/last h times/1st time h/last h
B@HANS times/1st time h/last h times/1st time h/last h
CA234 times/1st time h/last h times/1st time h/last h
Max. range of engine coolant temperature gauge Max. range of hydraulic oil temperature gauge
Items related to engine
Items related to oil pressure
20
(Travel speed : Lo)
2.0
15
12
7
4
Visual check of welded structure

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

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

(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspection Customer name:
T20606 Address:
Model PC400/450-8 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:
UEN02662-00

© 2007 KOMATSU
All Rights Reserved
16
UEN02646-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 5
UEN02646-00 40 Troubleshooting
Failure codes table 1

Action Alarm Device in Reference
Failure code Trouble (Displayed on screen) Category of record
code buzzer charge document No.
— A000N1 Eng. Hi Out of Std MON Mechanical system
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low MON Mechanical system
— B@BAZK Eng. Oil Level Low MON Mechanical system
— B@BCNS Eng. Water Overheat MON Mechanical system
— B@BCZK Eng. Water Lvl Low MON Mechanical system
E02 B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 EMC Critical Internal Failure ENG Electrical system
E11 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error q ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error q ENG Electrical system
E14 CA131 Throttle Sensor High Error q ENG Electrical system
E14 CA132 Throttle Sensor Low Error q ENG Electrical system
E15 CA135 Eng. Oil Press Sensor High Error q ENG Electrical system
E15 CA141 Eng. Oil Press Sensor Low Error q ENG Electrical system
E15 CA144 Coolant Temp Sens High Error q ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error q ENG Electrical system Troubleshooting
E15 CA153 Chg Air Temp Sensor High Error q ENG Electrical system by failure code
(Display of code),
E15 CA154 Chg Air Temp Sensor Low Error q ENG Electrical system Part 1
E15 CA187 Sens Supply 2 Volt Low Error q ENG Electrical system SEN02648-00
E15 CA221 Ambient Press Sens High Error q ENG Electrical system
E15 CA222 Ambient Press Sens Low Error q ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error q ENG Electrical system
— CA234 Eng Overspeed ENG Mechanical system
E15 CA238 Ne Speed Sens Supply Volt Error q ENG Electrical system
E15 CA263 Fuel Temp Sensor Hight Error q ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error q ENG Electrical system
E11 CA271 IMV/PCV1 Short Error q ENG Electrical system
E11 CA272 IMV/PCV1 Open Error q ENG Electrical system
E11 CA273 PCV2 Short Error q ENG Electrical system
E11 CA274 PCV2 Open Error q ENG Electrical system
E11 CA322 Inj #1 (L#1) Open/Short Error q ENG Electrical system
E10 CA342 Calibration Code Incompatibility q ENG Electrical system
Troubleshooting
E10 CA351 Injectors Drive Circuit Error q ENG Electrical system by failure code
E15 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system (Display of code),
E15 CA386 Sens Supply 1 Volt High Error q ENG Electrical system Part 2
SEN02649-00
E10 CA441 Battery Voltage Low Error q ENG Electrical system
40 Troubleshooting UEN02646-00

E10 CA442 Battery Voltage High Error q ENG Electrical system
E11 CA449 Rail Press Very High Error q ENG Electrical system
E11 CA451 Rail Press Sensor High Error q ENG Electrical system
E11 CA452 Rail Press Sensor Low Error q ENG Electrical system
E15 CA553 Rail Press High Error q ENG Electrical system
— CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error q ENG Electrical system
E11 CA689 Ne Speed Sensor Error q ENG Electrical system
E11 CA731 Bkup Speed Sens Phase Error q ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Bkup Speed Sensor Error q ENG Electrical system
E15 CA1228 EGR Valve Servo Error 1 q ENG Electrical system
E15 CA1625 EGR Valve Servo Error 2 q ENG Electrical system
E0E CA1633 KOMNET Datalink Timeout Error q ENG Electrical system Troubleshooting
E14 CA2185 Throt Sens Sup Volt High Error q ENG Electrical system by failure code
(Display of code),
E14 CA2186 Throt Sens Sup Volt Low Error q ENG Electrical system Part 2
E11 CA2249 Rail Press Very Low Error q ENG Electrical system SEN02649-00
E11 CA2271 EGR Valve Pos Sens High Error q ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error q ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error q ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error q ENG Electrical system
E15 CA2555 Grid Htr Relay Volt Low Error q ENG Electrical system
E15 CA2556 Grid Htr Relay Volt High Error q ENG Electrical system
— D110KB Battery Relay Drive S/C PUMP Electrical system
— D196KA Service Return Relay Disc. PUMP Electrical system
— D196KB Service Return Relay S/C PUMP Electrical system
E02 DA25KP Press. Sensor Power Abnormality q PUMP Electrical system
— DA80MA Auto Lub Abnormal PUMP Electrical system
E0E DA2RMC Pump Comm. Abnormality q PUMP Electrical system
— DA2SKQ Model Selection Abnormality q PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality q PUMP Electrical system
— DHPAMA F Pump P. Sensor Abnormality PUMP Electrical system
— DHPBMA R Pump P. Sensor Abnormality PUMP Electrical system
— DHS3MA Arm Curl PPC Sen. Abnormality PUMP Electrical system
— DHS4MA Bucket Curl PPC Sen. Abnormality PUMP Electrical system
— DW43KA Travel Speed Sol. Disc. PUMP Electrical system Troubleshooting
— DW43KB Travel Speed Sol. S/C PUMP Electrical system by failure code
(Display of code),
E03 DW45KA Swing Brake Sol. Disc. q PUMP Electrical system Part 3
E03 DW45KB Swing Brake Sol. S/C q PUMP Electrical system SEN02650-00
— DW91KA Travel Junction Sol. Disc. PUMP Electrical system
— DW91KB Travel Junction Sol. S/C PUMP Electrical system
— DWJ0KA Merge-divider Sol. Disc PUMP Electrical system
— DWJ0KB Merge-divider Sol. S/C PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system

— DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E02 DXA0KA PC-EPC Sol. Disc. PUMP Electrical system
E02 DXA0KB PC-EPC Sol. S/C PUMP Electrical system
— DXE0KA LS-EPC Sol. Disc. PUMP Electrical system
— DXE0KB LS-EPC Sol. S/C PUMP Electrical system Troubleshooting
— DXE4KA Service Current EPC Disc. PUMP Electrical system by failure code
(Display of code),
— DXE4KB Service Current EPC S/C PUMP Electrical system Part 3
— DY20KA Wiper Working Abnormality MON Electrical system SEN02650-00
— DY20MA Wiper Parking Abnormality MON Electrical system
— DY2CKB Washer Drive S/C MON Electrical system
— DY2DKB Wiper Drive (For) S/C MON Electrical system
— DY2EKB Wiper Drive (Rev) S/C MON Electrical system
a This failure codes table is the same as that in Testing and adjusting, Special functions of machine monitor.
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Fuse
Type of power supply Fusible link Fuse No. Destination of power
capacity
1 10A Work lamp relay, emergency switch
2 30A Solenoid valve
PPC oil pressure lock solenoid valve
F04 3 10A
Switch power supply Machine monitor
(65A)
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Auto preheater
7 10A Beacon
8 20A working lamp (boom), working lamp (rear)
F04 Radio, speaker
Switch power supply
(65A) Left knob switch (pump controller input)
9 10A
Quick coupler solenoid
Hydraulic ladder
10 10A Refuel pump
11 20A Air conditioner unit
12 20A Rear work lamp
13 20A Headlamp
F04
Switch power supply 14 30A Optional power supply (1), Auto grease
(65A)
Travel alarm, 12 V power supply
15 20A Optional power supply (2), heated seat, air suspension
seat
Radio (backup power supply)
16 10A
Room lamp
F05 Pump controller
Constant power supply 17 20A
(30A) Machine monitor
18 10A Electric priming pump
19 30A Engine controller
Starting switch
Switch power supply 20 5A Engine controller (ACC signal)
ACC
Location of fuse box and fuse Nos.
UEN02646-00

© 2007 KOMATSU
All Rights Reserved
8
UEN02647-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and troubleshooting steps......................................................................................................... 5
Information in troubleshooting table ................................................................................................................ 6
Wiring table for connector pin numbers .........................................................................................................11
T-adapter box and T-adapter table................................................................................................................ 44
Points to remember when troubleshooting 1

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 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
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 symp-
toms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
q Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be dis- Confirm the extent of the failure yourself, and
assembled. judge whether to handle it as a real failure or
q It will become impossible to find the cause as a problem with the method of operation, etc.
of the failure. a When operating the machine to reenact
It will also cause a waste of manhours, parts, the troubleshooting symptoms, do not
or oil or grease, and at the same time, will also carry out any investigation or measure-
lose the confidence of the user or operator. For ment that may make the problem worse.
this reason, when carrying out troubleshooting,
it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting Use the results of the investigation and inspec-
in accordance with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
of failure, then use the troubleshooting table or
2. Points to ask user or operator troubleshooting flowchart to locate the position
1) Have any other problems occurred apart of the failure exactly.
from the problem that has been reported? a The basic procedure for troubleshooting is
2) Was there anything strange about the as follows.
machine before the failure occurred? 1] Start from the simple points.
3) Did the failure occur suddenly, or were 2] Start from the most likely points.
there problems with the machine condition 3] Investigate other related parts or
before this? information.
4) Under what conditions did the failure
occur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before Even if the failure is repaired, if the root cause
the failure? When were these repairs car- of the failure is not repaired, the same failure
ried out? will occur again.To prevent this, always investi-
6) Has the same kind of failure occurred gate why the problem occurred. Then, remove
before? the root cause.
3. Check before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
Sequence of events in troubleshooting 1
Checks before troubleshooting 1
Item Criterion Remedy

1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of hydraulic oil level — Add oil
4. Check of hydraulic oil strainer — Clean and drain
Lubricating
5. Check of swing machinery oil level — Add oil
oil/Coolant
6. Check of level and type of engine oil (in oil pan) — Add oil
7. Check of coolant level — Add coolant
8. Check of dust indicator for clogging — Clean or replace
9. Check of hydraulic oil filter — Replace
1. Check of battery terminals and wiring for loose-
— Retighten or replace
ness and corrosion
Electrical 2. Check of alternator terminals and wiring for
equipment looseness and corrosion
3. Check of starting motor terminals and wiring for
looseness and corrosion
Hydraulic/ 1. Check for abnormal noise and smell — Repair

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

Classification of troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting steps
If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by
performing the following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [3] switch at panel switch section to display
failure code.
Carry out the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
2. Procedure for troubleshooting to be taken when failure code is recorded in abnormality record:
If an action code is not displayed on the machine monitor, check a failure code with the abnormality
record function of the machine monitor.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code
is recorded in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnor-
mality record, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out trouble-
shooting corresponding to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
Information in troubleshooting table 1

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

Display on Trouble name displayed in abnormality record machine moni-
Display on machine Trouble
machine monitor
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when engine con-
machine moni-
troller detects trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
Related circuit diagram
This drawing is a part of the electric circuit diagram related to trouble-

shooting.
q Connector No.: Indicates (Model – Number of pins) and
(Color).
q “Connector No. and pin No.” from each branching/merging
point: Shows the ends of branch or source of merging within
the parts of the same wiring harness.
q Arrow (⇔): Roughly shows the location on the machine.
Possible Problems and Troubleshooting No.
Troubleshooting
No. Phenomena looking like troubles Display of
E-mode H-mode S-mode
code
Phenomena related to action code and failure code
1 An action code is displayed on machine monitor
When abnormality record is checked, failure code is dis- According to
2
played in electrical system abnormality record displayed
When abnormality record is checked, failure code is dis- code
3
played in mechanical system abnormality record
Phenomena related to engine
4 Starting performance is poor (it always starts up slowly) S-1
5 Engine does not rotate E-1 S-2 (1)
Engine rotates, but exhaust gas does not
6 Engine does S-2 (2)
come out
not start
Engine emits exhaust gas, but it does not
7 S-2 (3)
start
Engine does not pick up smoothly (follow-up performance
8 S-3
is poor)
9 Engine stops during operations H-2 S-4
10 Engine rotation is unstable (it hunts) S-5
11 Engine lacks output or power H-1 S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive or exhaust smoke is blue S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
Oil is in coolant, coolant spurts back or coolant level goes
16 S-11
down
17 Oil level rises (Entry of coolant or fuel) S-13
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Auto-decelerator does not operate E-2 H-5
21 Automatic warm-up system does not operate E-3
22 Preheater does not operate E-4
Phenomena related to work equipment, swing and travel
Speed or power of whole work equipment, travel, and
23 H-1 S-6
swing is low
24 Engine speed lowers extremely or engine stalls H-2 S-4
Work equipment, swing, and travel mechanism do not
25 E-5 H-3
move
26 Abnormal sound comes out from around hydraulic pump H-4
27 Fine control performance or response is low H-6
Phenomena related to work equipment
28 Speed or power of boom is low E-18,19 H-7
29 Speed or power of arm is low E-20, 21 H-8
30 Speed or power of bucket is low E-22, 23 H-9
31 Boom, arm, or bucket does not move H-10
32 Hydraulic drift of work equipment is large H-11
Troubleshooting
code
33 Time lag of work equipment is large H-12
When part of work equipment is relieved singly, other parts
34 H-13
of work equipment move
35 Power maximizing function does not work E-6, 18 – 23 H-14
Phenomena related to compound operation
In compound operation of work equipment, speed of part
36 H-15
loaded more is low
When machine swings and raises boom simultaneously,
37 H-16
boom rising speed is low
When work equipment and travels simultaneously, travel
38 H-17
speed lowers largely
Phenomena related to travel
39 Machine deviates during travel H-18
40 Travel speed is low E-25 H-19
41 Machine is not steered well or steering power is low E-25, 26 H-20
42 Travel speed does not change or travel speed is low or high E-25 H-21
43 Travel system does not move (only one side) H-22
Phenomena related to swing
44 Upper structure does not swing E-24 H-23
45 Swing acceleration or swing speed is low H-24
Upper structure overruns remarkably when it stops swing-
46 H-25
ing
47 Large shock is made when upper structure stops swinging H-26
48 Large sound is made when upper structure stops swinging H-27
49 Hydraulic drift of swing H-28
Phenomena related to machine monitor (Operator menu: ordinary screen)
50 Machine monitor does not display any items E-7
51 Machine monitor does not display some items E-8
Contents of display by machine monitor are different from
52 E-9
applicable machine
Radiator coolant level monitor lights up in red during check
53 B@BCZK
before starting
Engine oil level monitor lights up in red during check
54 B@BAZK
before starting
Maintenance interval monitor lights up in red during check
55 See the Operation and Maintenance Manual.
before starting
Charge level monitor lights up in red while engine is run-
56 AB00KE
ning
57 Fuel level monitor lights up in red while engine is running E-10
Air cleaner clogging monitor lights up in red while engine is
58 AA10NX
running
Engine coolant temperature monitor lights up in red while
59 B@BCNS
engine is running
Hydraulic oil temperature monitor lights up in red while
60 B@HANS
engine is running
Engine coolant temperature gauge does not indicate nor-
61 E-11
mally
Troubleshooting
code
Hydraulic oil temperature gauge does not indicate nor-
62 E-12
mally
63 Fuel level gauge does not indicate normally E-13
64 Swing lock monitor does not indicate normally E-14
Machine monitor display anything even when operated on
65 E-15
monitor switch section
66 Windshield wiper does not operate E-16
67 Machine push-up function does not work normally E-17
Phenomena related to machine monitor (Service menu: special functions screen)
Monitoring function does not display “Boom RAISE” nor-
68 E-18
mally
Monitoring function does not display “Boom LOWER” nor-
69 E-19
mally
70 Monitoring function does not display “Arm IN” normally E-20
71 Monitoring function does not display “Arm OUT” normally E-21
Monitoring function does not display “Bucket CURL” nor-
72 E-22
mally
Monitoring function does not display “Bucket DUMP” nor-
73 E-23
mally
74 Monitoring function does not display “Swing” normally E-24
75 Monitoring function does not display “Travel” normally E-25
Monitoring function does not display “Travel Steering” nor-
76 E-26
mally
77 Monitoring function does not display “Service” normally E-27
Phenomena related to KOMTRAX
78 KOMTRAX system does not operate normally E-28
Others
79 Air conditioner does not operate E-29
80 Travel alarm does not sound or does not stop sounding E-30
81 Horn does not sound E-31
Wiring table for connector pin numbers (Rev. 2006. 11)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
T-adapter box and T-adapter table 1

(Rev. 2006. 11)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37
799-601-3200 T-box (for MS) 37
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for DT/HD) 12 q q q

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q q
Adapter for engine (CRI-T3) PFUEL
Socket for engine (CRI-T2)
799-601-9430 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440 Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530 Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190 3 1,2,3L q q
Commonrail pressure
799-601-4230 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240 Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250 Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330 Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
“*” Shows not T-adapter but socket.
UEN02647-00

© 2007 KOMATSU
All Rights Reserved
48
UEN02648-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Troubleshooting by failure code
(Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std ...................................................................................................... 3
Failure code [AA10NX] Air cleaner Clogging .................................................................................................. 4
Failure code [AB00KE] Charge Voltage Low .................................................................................................. 6
Failure code [B@BAZG] Eng Oil Press. Low.................................................................................................. 8
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. 10
Failure code [B@BCNS] Eng. Water Overheat............................................................................................. 12
Failure code [B@BCZK] Eng Water Level Low............................................................................................. 14
Failure code [B@HANS] Hydr Oil Overheat ................................................................................................. 16
Failure code [CA111] EMC Critical Internal Failure....................................................................................... 17
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 17
Failure code [CA122] Chg Air Press Sensor High Error ............................................................................... 18
Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................ 20
Failure code [CA131] Throttle Sensor High Error ......................................................................................... 22
Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 24
Failure code [CA135] Eng Oil Press Sensor High Error................................................................................ 26

Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................ 28
Failure code [CA144] Coolant Temp Sens High Error................................................................................... 30
Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 32
Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 34
Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 36
Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 38
Failure code [CA221] Ambient Press Sens High Error ................................................................................. 40
Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 42
Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 44
Failure code [CA234] Eng Overspeed .......................................................................................................... 45
Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 46
Failure code [CA263] Fuel Temp Sensor High Error..................................................................................... 48
Failure code [CA265] Fuel Temp Sensor Low Error...................................................................................... 50
Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 51
Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 52
Failure code [CA273] PCV2 Short Error ....................................................................................................... 54
Failure code [CA274] PCV2 Open Error ....................................................................................................... 55
Failure code [CA322] Inj #1 Open/Short Error .............................................................................................. 56
Failure code [A000N1] Eng. Hi Out of Std 1
Action code Failure code Engine high idle out of standard

Trouble
— A000N1 (Mechanical system)
Contents of
• While the engine was running, engine speed exceeded 2,350 rpm for more than 10 seconds.
trouble
Action of • None in particular.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
Related • Input from the engine speed sensor (engine speed) can be checked with monitoring function.
information (Code 010: Engine speed)

Check for any internal or external factor that might cause the exces-
Possible causes Defective engine mechani-
1 sive engine high idle speed for troubleshooting of engine mechani-
and standard cal system
cal system.
value in normal
state Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective engine controller no visible error appears on the machine, the controller can be con-
tinuously used as it is.)
Failure code [AA10NX] Air cleaner Clogging 1
Action code Failure code Air cleaner clogging

Trouble
— AA10NX (Machine monitor system)
Contents of • While engine was running, signal circuit of air cleaner clogging switch detected clogging of air
trouble cleaner (sensor contact opened).
Action of • Displays air cleaner clogging monitor on machine monitor.
Problem that
machine
• Condition of air cleaner clogging switch signal can be checked with monitoring function.
Related
(Code: 04501 Monitor input 2)
information
• Method of reproducing failure code: Start engine.

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

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

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

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

Lowering of engine oil pres-
a Determine the cause and check the damage to the engine and
1 sure
then modify it.
(when system is normal)
Defective engine oil pressure
2 sensor POIL (male) Engine Resistance
(Internal defect) When started Min. 1Mz
sis ground When stopped Max. 1 z
Possible causes ness ing without turning starting switch ON.
and standard 3 (Disconnection in wiring or
value in normal defective contact in connec- Wiring harness between CE01 (female) (13) Resist- Max. 1 z
state tor) – POIL (female) (3) ance
a Prepare with starting switch OFF, then carry out troubleshoot-

Ground fault in wiring har- ing without turning starting switch ON.
ness
4 Wiring harness between CE01 (female) (13)
cuit) – POIL (female) (3) and chassis ground Min. 1Mz
ance
(when engine is started)
5 Defective engine controller CE01 Engine Resistance
Between (13) – chas- When started Min. 1Mz
sis ground When stopped Max. 1 z
Circuit diagram related to engine oil pressure of machine monitor
Failure code [B@BAZK] Eng Oil Level Low 1
Action code Failure code Engine oil level low

Trouble
— B@BAZK (Machine monitor system)
Contents of • When starting switch is turned ON (but engine is not started), signal circuit of engine oil level switch
trouble detected low engine oil level (sensor contact opened).
Action of • Displays engine oil level monitor on machine monitor.
Problem that
machine
• Engine oil level switch signal can be checked with monitoring function.
Related
(Code 04501: Monitor Input 2)
information
• Method of reproducing failure code: Turn starting switch ON.

Lowering of engine oil level a Check the engine oil level and add new oil.
1
(when system is normal) (If this phenomenon frequently occurs, investigate the cause.)
ing without turning starting switch ON.
Defective engine oil level P44 (male) Engine oil level Resistance
2 switch
(Internal disconnection) Value in normal state Max. 1 z
sis ground Value when oil level is
Min. 1Mz
Possible causes low
and standard
value in normal
state
defective contact in connec- Wiring harness between CM02 (female) (2) – Resist- Max. 1 z
tor) P44 (female) (1) ance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
CM02 Engine oil level Voltage
4 Defective machine monitor
Value in normal state Max. 1 V
sis ground Value when oil level is
20 – 30 V
low
Circuit diagram related to engine oil level switch of machine monitor
Failure code [B@BCNS] Eng. Water Overheat 1
Action code Failure code Engine coolant overheat

Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating
trouble of engine coolant (above about 102°C).
Action of • Displays engine coolant temperature monitor with red on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may seize up.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Related
• Engine coolant temperature can be checked with monitoring function
information
(Code: 04107 Engine coolant temperature)

Overheating of engine
Possible causes Engine coolant may be overheating. Check it and remove cause if it
1 coolant (when system is nor-
and standard is overheating.
mal)
value in normal
state If cause 1 is not detected, engine coolant temperature gauge sys-
Defective engine coolant
2 tem may be defective. Carry out troubleshooting for "[CA144]
temperature gauge system
[CA145]" in troubleshooting.
Circuit diagram related to engine coolant temperature sensor of machine monitor
Failure code [B@BCZK] Eng Water Level Low 1
Action code Failure code Engine coolant level low

Trouble
— B@BCZK (Machine monitor system)
Contents of • When starting switch is turned ON, signal circuit of radiator coolant level sensor detected low radiator
trouble coolant level (sensor contact opened).
Action of • Displays radiator coolant level monitor on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may overheat.
machine
• Condition of radiator coolant level switch can be checked with monitoring function
Related
(Code: 04500 Monitor input 1)
information

Lowering of radiator coolant
a Check the coolant level and add coolant.
1 level
(If this phenomenon frequently occurs, investigate the cause.)
(when system is normal)
Defective radiator coolant P24 (male) Radiator coolant level Resistance
2 level switch (internal discon-
nection) Value in normal state Max. 1 z
Between (1) – (2) Value when coolant
Min. 1Mz
level is low
Possible causes
and standard Disconnection in wiring har- ing without turning starting switch ON.
state Wiring harness between P02 (female) (3) – Resist-
tor) Wiring harness between P24 (female) (2) – Resist-
Max. 1 z
chassis ground ance
Engine coolant tem-
P02 Voltage
4 Defective machine monitor perature
Value in normal state Max. 1 V
sis ground Value when coolant
20 – 30 V
level is low
Circuit diagram related to radiator coolant level switch of machine monitor
Failure code [B@HANS] Hydr Oil Overheat 1
Action code Failure code Hydraulic oil overheat

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

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

Trouble
E10 CA111 (Engine controller system)
Contents of
• Memory or power supply circuit in engine controller is defective.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Engine controller may be defective. (Since trouble is in system, trou-
1 Defective engine controller
state bleshooting cannot be carried out.)
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1
Action code Failure code Engine Ne and Bkup speed sensor error
Trouble
Contents of
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related
information

and standard Connectors of Ne speed sensor and Bkup speed sensor may be
value in normal Defective connection of sen-
1 connected defectively (or connected to wrong parts). Check them
state sor connector
directly.
Failure code [CA122] Chg Air Press Sensor High Error 1
Action code Failure code Charge air pressure sensor high error
Trouble
Contents of
• Pressure signal circuit of boost pressure sensor detected high voltage.
trouble
Action of
• Fixes charge pressure value and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related
information

Defective sensor power sup- If failure code [CA227] is also indicated, carry out troubleshooting
1
ply 2 system for it first.
Defective boost pressure PIM (male) Voltage
2 sensor [pressure signal sys- Between (2) – (3) Power supply 4.75 – 5.25 V
tem]
Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short in wiring harness and carry out troubleshooting.
3 (Short circuit with 5V/24V cir-
Possible causes Wiring harness between CE01 (female) (44)
cuit) Voltage Max. 1 V
and standard – PIM (female) (2) and chassis ground
value in normal
state
Short circuit in wiring har- ing without turning starting switch ON.
4 ness Wiring harness between CE01 (female) (44)
(with another wiring harness) – PIM (female) (2) and between CE01 Resist- Min.
ance 100 kz
(female) (37) – PIM (female) (1)
Connecting parts between boost pressure sensor – engine wiring
harness – engine controller may be defective. Check them directly.
Defective wiring harness
5 • Looseness of connector, breakage of lock, or breakage of seal
connector
• Corrosion, bend, breakage, push-in, or expansion of pin
• Moisture or dirt in connector or defective insulation
CE01 Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
Circuit diagram related to boost pressure sensor
Failure code [CA123] Chg Air Press Sensor Low Error 1
Action code Failure code Charge air pressure sensor low error
Trouble
Contents of
• Pressure signal circuit of boost pressure sensor detected low voltage.
trouble
Action of
• Fixes charge pressure value and continues operation.
controller
Problem that
machine
Related
information

1
Defective boost pressure PIM (male) Voltage
2 sensor [pressure signal sys- Between (2) – (3) Power supply 4.75 – 5.25 V
tem]
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
3
Possible causes (Short circuit with GND cir- Wiring harness between CE01 (female) (44) Resist- Min.
and standard cuit) – PIM (female) (2) and chassis ground ance 100 kz
value in normal
state
(with another wiring harness) – PIM (female) (2) and between CE01 Resist- Min.
ance 100 kz
(female) (47) – PIM (female) (1)
Connecting parts between boost pressure sensor – engine wiring
connector
CE01 Voltage
Circuit diagram related to boost pressure sensor
Failure code [CA131] Throttle Sensor High Error 1
Action code Failure code Throttle sensor high error

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

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

Trouble
Contents of
• Signal circuit of fuel control dial detected low voltage.
trouble
Problem that
machine
• Signal voltage of fuel control dial can be checked with monitoring function. (Code: 03000 Fuel con-
Related
trol dial voltage)
information

Defective throttle sensor If failure code [CA2186] is also indicated, carry out troubleshooting
1
P20 (male) Voltage
2 Defective fuel control dial Between (1) – (3) Power supply 4.75 – 5.25 V
3
Possible causes (Short circuit with GND cir- Wiring harness between CE02 (female) (9) – Min.
and standard cuit) Voltage
P20 (female) (2) and chassis ground 100 kz
value in normal
state
(with another wiring harness) P20 (female) (2) and between CE02 (female) Resist- Min.
ance 100 kz
(23) – P20 (female) (3)
Connecting parts between fuel control dial – machine wiring har-
connector
CE02 Voltage
Failure code [CA135] Eng Oil Press Sensor High Error 1

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

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting in each case.
POIL Voltage
Defective oil pressure sensor
2 Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out trouble-
shooting without turning starting switch ON.
Wiring harness between ENG (female) (37) – Resist-
Disconnection in wiring harness Max. 1 z
POIL (female) (1) ance
defective contact in connector) Wiring harness between ENG (female) (47) – Resist-
Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal Between wiring harness of ENG (female) Resist-
Min. 1 Mz
state Ground fault in wiring harness (37) – POIL (female) (1) and chassis ground ance
3
(Short circuit with GND circuit) Between wiring harness of ENG (female) Resist-
Min. 1 Mz
(47) – POIL (female) (2) and chassis ground ance
Between wiring harness of ENG (female) Resist-
Min. 1 Mz
(13) – POIL (female) (3) and chassis ground ance
Wiring harness between ENG (female) (37) –
Resist-
POIL (female) (1) and between ENG Min. 1 Mz
ance
(female) (47) – POIL (female) (2)
Short circuit in wiring harness
4
(with another wiring harness) Wiring harness between ENG (female) (37) – Resist-
ance
Resist-
ance
a Prepare with starting switch OFF, then turn starting
switch ON or start engine and carry out troubleshooting.
ENG Voltage
Circuit diagram related to oil pressure sensor
Failure code [CA141] Eng Oil Press Sensor Low Error 1

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

and standard
value in normal Carry out troubleshooting for failure code [CA135].
state
Failure code [CA144] Coolant Temp Sens High Error 1
Action code Failure code Coolant temperature sensor high error

Trouble
Contents of
• Signal circuit of coolant temperature sensor detected high voltage.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that
• Exhaust gas becomes white.
appears on
Overheat prevention function does not work.
machine
Related
information

Defective coolant tempera- ing without turning starting switch ON.
1
ture sensor TWTR (male) Resistance
Between (A) – (B) 0.18 – 160 kz
Disconnection in wiring har- ing without turning starting switch ON.
ness
Wiring harness between CE01 (female) (15) Resist-
– TWTR (female) (A) ance
tor) Wiring harness between CE01 (female) (38) Resist-
Max. 10 z
– TWTR (female) (B) ance
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
and standard
value in normal
state 3 ness Between CE01 (female) (15) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resist- Min.
ance 100 kz
nectors disconnected)
Connecting parts between coolant temperature sensor – engine wir-
ing harness – engine controller may be defective. Check them
Defective wiring harness directly.
4
connector • Looseness of connector, breakage of lock, or breakage of seal
CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
Circuit diagram related to engine coolant temperature sensor
Failure code [CA145] Coolant Temp Sens Low Error 1
Action code Failure code Coolant temperature sensor low error

Trouble
Contents of
• Signal circuit of coolant temperature sensor detected low voltage.
trouble
Action of
• Fixes coolant temperature value and continues operation.
controller
Problem that
appears on
• Overheat prevention function does not work.
machine
Related
information

Defective coolant tempera- TWTR (male) Resistance
1
ture sensor
Between (A) – (B) 0.18 – 160 kz
Between (B) – chassis ground Min. 100 kz
2
(Short circuit with GND cir- Wiring harness between CE01 (female) (15) Resist- Min.
cuit) – TWTR (female) (A) and chassis ground ance 100 kz
Possible causes ing without turning starting switch ON.
Short circuit in wiring har-
and standard
3 ness Between CE01 (female) (15) – each of CE01
value in normal Resist- Min.
(with another wiring harness) (female) pins (With all wiring harness con-
state ance 100 kz
Connecting parts between coolant temperature sensor – engine wir-
4
5 Defective engine controller CE01 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
Failure code [CA153] Chg Air Temp Sensor High Error 1
Action code Failure code Charge air temperature sensor high error
Trouble
Contents of
• Temperature signal circuit of boost temperature sensor detected high voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
appears on
• Engine protection function based on boost temperature does not work
machine
Related
information

Defective boost temperature ing without turning starting switch ON.
1 sensor [temperature signal
TIM (male) Resistance
system]
Between (A) – (B) 0.18 – 160 kz
ness
– TIM (female) (A) ance
Max. 10 z
– TIM (female) (B) ance
and standard
value in normal
state 3 ness Between CE01 (female) (23) – each of CE01
(with another wiring harness) (female) pins (With all wiring harness con- Resist- Min.
ance 100 kz
Connecting parts between boost temperature sensor – engine wir-
4
Between (23) – (47) 0.18 – 160 kz
Circuit diagram related to boost temperature sensor
Failure code [CA154] Chg Air Temp Sensor Low Error 1
Action code Failure code Charge air temperature sensor low error
Trouble
Contents of
• Temperature signal circuit of boost temperature sensor detected low voltage.
trouble
Action of
• Fixes charge temperature value and continues operation.
controller
Problem that
appears on
• Engine protection function based on boost temperature does not work
machine
Related
information

Defective boost temperature
1 sensor [temperature signal TIM (male) Resistance
system] Between (A) – (B) 0.18 – 160 kz
Between (A) – chassis ground Min. 100 kz
2
cuit) – TIM (female) (A) and chassis ground ance 100 z
Possible causes ing without turning starting switch ON.
and standard
value in normal Resist- Min.
(with another wiring harness) (female) pins (With all wiring harness con-
state ance 100 kz
Connecting parts between boost temperature sensor – engine wir-
4
Between (23) – (47) 0.18 – 160 kz
Between (23) – chassis ground Min.100 z
Circuit diagram related to boost temperature sensor
Failure code [CA187] Sens Supply 2 Volt Low Error 1
Action code Failure code Sensor power supply 2 voltage low error
Trouble
Contents of
• Low voltage was detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

a Disconnect connector with starting switch OFF, then turn start-
ing switch ON and carry out troubleshooting.
Boost pressure sen-

PIM
Disconnect sensor sor
and wiring harness at
right in order and Boost temperature
TIM
carry out operation to sensor
Defective sensor or wiring
1 reproduce trouble. If
harness Common rail pres-
“E” of failure code PFUEL
sure sensor
Possible causes goes off when sensor
and standard or wiring harness is
value in normal disconnected, that Bkup sensor G
state sensor or wiring har-
ness is defective. Engine wiring har-
CE01
ness
Connecting parts between each sensor – engine wiring harness –

engine controller may be defective. Check them directly.
connector
If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
Circuit diagram related to sensor power supply 2
Failure code [CA221] Ambient Press Sens High Error 1
Action code Failure code Ambient pressure sensor high error

Trouble
Contents of
• High voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
• Fixes ambient pressure value and continues operation.
controller
Problem that
• Engine output lowers.
appears on
• Engine starting performance becomes deteriorated.
machine
Related
information

1
PAMB (male) Voltage
Defective ambient pressure
sensor
Hot short (Short circuit with and carry out troubleshooting.
3 5V/24V circuit) in wiring har-
Possible causes Wiring harness between CE01 (female) (3) –
ness Voltage Max. 1 V
and standard PAMB (female) (2) and chassis ground
value in normal
state
(with another wiring harness) PAMB (female) (2) and between CE01 Resist- Min.
ance 100 kz
(female) (37) – PAMB (female) (1)
Connecting parts between ambient pressure sensor – engine wiring
connector
CE01 Voltage
Circuit diagram related to atmospheric pressure sensor
Failure code [CA222] Ambient Press Sens Low Error 1
Action code Failure code Ambient pressure sensor low error

Trouble
Contents of
• Low voltage was detected in signal circuit of ambient pressure sensor.
trouble
Action of
controller
Problem that
appears on
• Engine starting performance becomes deteriorated.
machine
Related
information

1
PAMB (male) Voltage
Defective ambient pressure
sensor
3
Possible causes (Short circuit with GND cir- Wiring harness between CE01 (female) (3) – Resist- Min.
and standard cuit) PAMB (female) (2) and chassis ground ance 100 kz
value in normal
state
(with another wiring harness) PAMB (female) (2) and between CE01 Resist- Min.
ance 100 kz
(female) (38) – JM03 – PAMB (female) (3)
connector
CE01 Voltage
Circuit diagram related to atmospheric pressure sensor
Failure code [CA227] Sens Supply 2 Volt High Error 1
Action code Failure code Sensor power supply 2 voltage high error
Trouble
Contents of
• High voltage was detected in sensor power supply 2 circuit.
trouble
Action of • Fixes charge pressure and charge temperature values and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

Possible causes engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
If cause 1 is not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
Failure code [CA234] Eng Overspeed 1
Action code Failure code Engine overspeed

Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded control upper speed limit.
trouble
Action of
• Stops injection until engine speed lowers to normal level.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
• Method of reproducing failure code: Run engine at high idle.
information

Possible causes 1 Use of improper fuel Fuel used may be improper. Check it directly.
and standard Machine may be used improperly. Teach operator proper using
value in normal 2 Improper use
method.
state
Failure code [CA238] Ne Speed Sens Supply Volt Error 1
Action code Failure code Ne speed sensor supply power voltage error
Trouble
Contents of
• Low voltage was detected in power supply circuit of engine Ne speed sensor.
trouble
Action of
• Controls the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine does not start easily.
appears on
• Engine hunts.
machine
Related
information

Disconnect sensor
right in order and Ne speed sensor NE
Defective sensor or wiring carry out operation to
Possible causes harness
and standard “E” of failure code
value in normal goes off when sensor
state or wiring harness is Engine wiring har-
disconnected, that CE01
ness
sensor or wiring har-
ness is defective.
connector
Circuit diagram related to engine Ne speed sensor
Failure code [CA263] Fuel Temp Sensor High Error 1

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

Defective fuel temperature shooting without turning starting switch ON.
1 sensor
TFUEL (male) Fuel temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring harness
Possible causes 2 (Disconnection in wiring or Max. 1 z
defective contact in connector) TFUEL (female) (A) ance
and standard
value in normal Wiring harness between ENG (female) (47) – Resist-
Max. 1 z
state TFUEL (female) (B) ance
Ground fault in wiring harness Wiring harness between ENG (female) (30) – Resist-
3 Min. 1 Mz
(Short circuit with GND circuit) TFUEL (female) (A) and chassis ground ance
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
Circuit diagram related to fuel temperature sensor
Failure code [CA265] Fuel Temp Sensor Low Error 1

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

and standard
state
Failure code [CA271] IMV/PCV1 Short Error 1

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

Defective supply pump
PCV1 (male) Resistance
1 PCV1
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Min. 1 Mz
(Short circuit with GND circuit) PCV1 (female) (1) and chassis ground ance
Possible causes
and standard Min. 1 Mz
PCV1 (female) (2) and chassis ground ance
value in normal
state a Prepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Hot short in wiring harness Wiring harness between ENG (female) (4) –
3 Voltage Max. 1 V
(Short circuit with 24V circuit) PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
ENG (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Circuit diagram related to supply pump PCV1
Failure code [CA272] IMV/PCV1 Open Error 1

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

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
defective contact in connector) PCV1 (female) (1) ance
Possible causes Max. 1 z
PCV1 (female) (2) ance
and standard
value in normal a Prepare with starting switch OFF, then carry out trouble-
state shooting without turning starting switch ON.
Between wiring harness of ENG (female) (4) –
Resist- Max. 1
Ground fault in wiring harness PCV1 (female) (1) and chassis ground and
3 ance Mz
(Short circuit with GND circuit) chassis ground
Between wiring harness of ENG (female) (5) –
Resist- Max. 1
PCV1 (female) (2) and chassis ground and
ance Mz
chassis ground
Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Failure code [CA273] PCV2 Short Error 1

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

Defective supply pump
1 PCV2
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
2 Min. 1 Mz
Possible causes
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Hot short in wiring harness Wiring harness between ENG (female) (9) –
3 Voltage Max. 1 V
(Short circuit with 24V circuit) PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
PCV2 (female) (2) and chassis ground
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
Failure code [CA274] PCV2 Open Error 1

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

Defective supply pump shooting without turning starting switch ON.
1 PCV2
(Internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
defective contact in connector) PCV2 (female) (1) ance
PCV2 (female) (2) ance
and standard
value in normal a Prepare with starting switch OFF, then carry out trouble-
state shooting without turning starting switch ON.
3 Min. 1 Mz
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
Failure code [CA322] Inj #1 Open/Short Error 1
Action code Failure code Injector #1 open/short circuit error

Trouble
Contents of
• Opening or short circuit was detected in drive circuit of No. 1 injector.
trouble
Action of
controller
Problem that
• Combustion becomes irregular or engine hunts.
appears on
machine
Related
information

If following failure codes are also displayed, trouble is in engine con-
troller: [CA322], [CA324], [CA331]
2 Defective No. 1 injector CN1 (male) Resistance
Between (1) – (2) Max. 2 z
ness
– CN1 (female) (1) ance
Max. 2 z
Possible causes 4
(Short circuit with GND cir- Wiring harness between CE01 (female) (45) Resist-
and standard cuit) Max. 2 z
– CN1 (female) (1) and chassis ground ance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
Between CE01 (female) (45) – each of CE01
Short circuit in wiring har- Resist- Min.
(female) pins (With all wiring harness con-
5 ness ance 100 kz
(with another wiring harness)
Resist- Min.
ance 100 kz
Connecting parts between No. 1 injector – engine wiring harness –
connector
Between (45) – (53) Max. 2 z
Circuit diagram related to injector No. 1

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

troller: [CA323], [CA325], [CA332]
ness
Max. 2 z
Possible causes 4
value in normal
5 ness ance 100 kz
Resist- Min.
ance 100 kz
connector
Between (46) – (60) Max. 2 z

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

troller: [CA322], [CA324], [CA331]
ness
Max. 2 z
Possible causes 4
value in normal
5 ness ance 100 kz
Resist- Min.
ance 100 kz
connector
Between (55) – (52) Max. 2 z

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

troller: [CA323], [CA325], [CA332]
ness
Max. 2 z
Possible causes 4
value in normal
5 ness ance 100 kz
Resist- Min.
ance 100 kz
connector
Between (57) – (59) Max. 2 z

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

If following failure codes are also displayed, trouble is in engine
controller: [CA322], [CA324], [CA331]
ness
Max. 2 z
Possible causes 4
value in normal
5 ness ance 100 kz
Resist- Min.
ance 100 kz
connector
Between (54) – (51) Max. 2 z

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

troller: [CA323], [CA325], [CA332]
ness
Max. 2 z
Possible causes 4
value in normal
5 ness ance 100 kz
Resist- Min.
ance 100 kz
connector
Between (56) – (58) Max. 2 z
UEN02648-00

© 2007 KOMATSU
All Rights Reserved
68
UEN02649-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Failure code [CA342] Calibration Code Incompatibility................................................................................... 3
Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 8
Failure code [CA441] Battery Voltage Low Error .......................................................................................... 10
Failure code [CA442] Battery Voltage High Error ......................................................................................... 12
Failure code [CA449] Rail Press Very High Error ......................................................................................... 14
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 18
Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 20
Failure code [CA553] Rail Press High Error ................................................................................................. 22
Failure code [CA554] Rail Press Sensor In Range Error.............................................................................. 23
Failure code [CA559] Rail Press Low Error .................................................................................................. 24
Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 26
Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 28
Failure code [CA757] All Persistent Data Lost Error ..................................................................................... 30

Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 32
Failure code [CA1228] EGR valve servo error 1........................................................................................... 34
Failure code [CA1625] EGR valve servo error 2........................................................................................... 35
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 36
Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 39
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 40
Failure code [CA2271] EGR valve lift sensor high error ............................................................................... 42
Failure code [CA2272] EGR valve lift sensor low error ................................................................................. 44
Failure code [CA2351] EGR valve solenoid operation short circuit .............................................................. 46
Failure code [CA2352] EGR valve solenoid operation disconnect................................................................ 48
Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 50
Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 52
Failure code [D110KB] Battery Relay Drive S/C ........................................................................................... 54
Failure code [DA25KP] 5V sensor power supply output 1 abnormality......................................................... 56
Failure code [DA2RMC] Pump Comm. Abnormality ..................................................................................... 60
Failure code [DA2SKQ] Model Selection Abnormality .................................................................................. 62
Failure code [CA342] Calibration Code Incompatibility 1
Action code Failure code Calibration code incompatibility

Trouble
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Normal operation, engine stopped, or start disabled
machine
Related
information

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

Trouble
Contents of
• There is error in drive power circuit of injector.
trouble
Action of
• Limits output and continues operation.
controller
• Exhaust gas becomes black.
Problem that
• Combustion becomes irregular.
appears on
machine
• Engine cannot be started.
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
2 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Defective relay for engine
3 Replace relay (R23, R24) for engine controller with another relay
controller power supply
and perform reproducing operation. If “E” of failure code goes off at
Possible causes this time, replaced relay is defective.
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resist- Max.
ness (female) (3) ance 0.5 z
defective contact in connec- Wiring harness between R23, R24 (female) Resist- Max.
tor) (5) – CE03 (female) (3) ance 0.5 z
Wiring harness between CE03 (female) (1) – Resist- Max.
chassis ground (T11) ance 10 z
If causes 1 – 4 are not detected, engine controller may be defective.
Circuit diagram related to engine controller power supply
Failure code [CA352] Sens Supply 1 Volt Low Error 1
Action code Failure code Sensor power supply 1 voltage low error
Trouble
Contents of
• Low voltage was detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Disconnect sensor
right in order and Ambient pressure
PAMB
carry out operation to sensor
Defective sensor or wiring
harness
“E” of failure code
Possible causes goes off when sensor
and standard or wiring harness is Engine wiring har-
value in normal disconnected, that CE01
ness
state sensor or wiring har-
ness is defective.
connector
out.)
Failure code [CA386] Sens Supply 1 Volt High Error 1
Action code Failure code Sensor power supply 1 voltage high error
Trouble
Contents of
• High voltage was detected in sensor power supply 1 circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Possible causes harness – engine controller may be defective. Check them directly.
and standard 1 • Looseness of connector, breakage of lock, or breakage of seal
connector
value in normal • Corrosion, bend, breakage, push-in, or expansion of pin
state • Moisture or dirt in connector or defective insulation
Failure code [CA441] Battery Voltage Low Error 1

Action code Failure code Battery voltage low error
Trouble
Contents of
• There is low voltage in controller power supply circuit.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
machine
Related
information

Looseness or corrosion of
1 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in
each case.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
3 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault. (See Cause 6)
this time, replaced relay is defective.
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resist-
ness (female) (3) ance
and standard
value in normal Wiring harness between R23, R24 (female) Resist-
defective contact in connec- Max. 10 z
state (5) – CE03 (female) (3) ance
tor)
Wiring harness between CE03 (female) (1) – Resist-
Max. 10 z
chassis ground (T11) ance
ness Wiring harness between F01-19 – R23, R24 Resist- Min.
6
(Short circuit with GND cir- (female) (3) and chassis ground ance 100 kz
cuit)
Wiring harness between R23, R24 (female) Resist- Max.
(5) – CE03 (female) (3) and chassis ground ance 10 z
Between CE03 (female) (3) – CE03 (female) Resist- Min.
(1) pins (With battery terminal disconnected) ance 100 kz
Resist- Min.
(with another wiring harness) (female) pins (With battery terminal discon- ance 100 kz
nected)
Resist- Min.
(female) pins (With battery terminal discon-
ance 100 kz
nected)

Connecting parts between fuse No. 19 – machine wiring harness –
connector
Possible causes • Corrosion, bend, breakage, push-in, or expansion of pin
and standard • Moisture or dirt in connector or defective insulation
state and start engine and carry out troubleshooting in each case.
9 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
Failure code [CA442] Battery Voltage High Error 1
Action code Failure code Battery voltage high error

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

1 Defective battery voltage
Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry
and standard out troubleshooting.
value in normal 2 Defective alternator Alternator Engine speed Voltage
state
R terminal – chassis
Medium or higher 27.5 – 29.5 V
ground
CE03 (female) Voltage
Between (3) – (1) Max. 32 V
Failure code [CA449] Rail Press Very High Error 1
Action code Failure code Common rail pressure very high error
Trouble
Contents of
• There is high pressure error (2) in common rail circuit.
trouble
Action of
controller
Problem that
machine
Related
information

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

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

1
PFUEL (male) Voltage
Defective common rail pres-
sure sensor
Possible causes ness Wiring harness between CE01 (female) (25)
Voltage Max. 1 V
and standard – PFUEL (female) (2) and chassis ground
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state Short circuit in wiring har- ing without turning starting switch ON.
4 ness Wiring harnesses between CE01 (female)
(with another wiring harness) (25) – PFUEL (female) (2) and between Resist- Min.
ance 100 kz
CE01 (female) (33) – PFUEL (female) (1)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
Circuit diagram related to common rail pressure sensor
Failure code [CA452] Rail Press Sensor Low Error 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• There is low voltage in signal circuit of common rail pressure sensor.
trouble
Action of
controller
Problem that
• Engine speed or output lowers.
appears on
machine
Related
information

1
PFUEL (male) Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- a Prepare with starting switch OFF, then turn starting switch ON
ness and carry out troubleshooting.
3
Possible causes
cuit) – PFUEL (female) (2) and chassis ground ance 100 kz
and standard
state Short circuit in wiring har- ing without turning starting switch ON.
(with another wiring harness) – PFUEL (female) (2) and between CE01 Resist- Min.
ance 100 kz
(female) (47) – PFUEL (female) (3)
Connecting parts between common rail pressure sensor – engine
wiring harness – engine controller may be defective. Check them
5
CE01 Voltage
Circuit diagram related to common rail pressure sensor
Failure code [CA553] Rail Press High Error 1
Action code Failure code Common rail pressure high error

Trouble
Contents of
• There is high pressure error (1) in common rail circuit.
trouble
Action of
controller
Problem that
• Engine sound becomes large when no or light load is applied.
appears on
machine
Related
information

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

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

and standard
state
Failure code [CA559] Rail Press Low Error 1
Action code Failure code Common rail pressure low error

Trouble
Contents of
• There is low pressure error (1) in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Exhaust gas becomes black.
machine • Engine output lowers.
Related
information

Fuel may be leaking to outside. Check it directly (Check visually
1 Fuel leakage to outside
while running engine at low idle).
• Measured in fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Pressure in fuel low- Min. 0.14 MPa
During cranking
pressure circuit {Min. 1.4 kg/cm2}
• Measured in fuel filter outlet side.
Pressure in fuel low- Min. 0.48 MPa
During high idle
pressure circuit {Min. 4.9 kg/cm2}
Possible causes
and standard and adjusting, Checking fuel pressure.
value in normal • Measured in fuel filter inlet and outlet sides.
state Defect in low pressure cir- • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pres-
2 sure — Fuel filter outlet pressure
cuit parts
Pressure drop in fuel Max. 0.14 MPa
During high idle
low-pressure circuit {Max. 1.4 kg/cm2}
• Measured in gear pump fuel inlet side of supply pump.
Max. 33.9 kPa
pressure (gear pump During high idle
{Max. 254 mmHg}
side)
• Measured in fuel connector side.
Max. 27.1 kPa
pressure (fuel con- During high idle
{Max. 203 mmHg}
nector side)

a For check of return rate from injector, see Testing and adjust-
ing, Checking fuel return rate and leakage.
During cranking
Defective injector
(if engine cannot be Max. 100 cc/30 sec.
3 (including high pressure pip-
Return rate from started)
ing in head)
injector During low idle
(if engine can be Max. 300 cc/45 sec.
started)
a For check of return rate from supply pump, see Testing and
adjusting, Checking fuel return rate and leakage.
During cranking
(if engine cannot be Max. 100 cc/30 sec.
4 Defective supply pump
Return rate from sup- started)
Possible causes ply pump During low idle
and standard (if engine can be Max. 300 cc/45 sec.
value in normal started)
state a For check of leakage through pressure limiter, see Testing and
adjusting, Checking fuel return rate and leakage.
5 Defective pressure limiter
Leakage through
During cranking Max. 30 cc/min
pressure limiter
Defective supply pump a Remove the supply pump head, and directly check that the
6
plunger plunger is not damaged.
There may be air in low pressure circuit. Check it directly according
to the following procedure.
1) Remove pressure pickup plug (outlet side) of fuel main filter.
2) Operate feed pump of fuel pre-filter.
3) Check pressure pickup plug for leakage of fuel and air.
7 Air in low pressure circuit
• If this error occurs during air bleeding after the fuel filter was
replaced, air may remain in the fuel circuit. Keep running the
engine at low idle for about three minutes. As air is bled from the
fuel circuit, the engine speed will be stabilized, erasing the error
indication.
Failure code [CA689] Eng Ne Speed Sensor Error 1
Action code Failure code Engine Ne speed sensor error

Trouble
Contents of
• There is error in signal from engine Ne speed sensor.
trouble
Action of
• Continues control with signal from engine Bkup speed sensor.
controller
Problem that • Engine hunts.
appears on • Engine does not start easily.
Related
information

Defective Ne speed sensor If failure code [CA238] is also indicated, carry out troubleshooting
1
NE (male) Voltage
Defective engine Ne speed
sensor
Breakage or improper clear-
Engine Ne speed sensor may be broken or may have improper
3 ance of engine Ne speed
clearance. Check it directly.
Possible causes sensor
and standard Breakage of rotation sensor
value in normal 4 Rotation sensor wheel may be broken. Check it directly.
wheel
state
defective contact in connec- Wiring harness between CE01 (female) (27) Resist- Max. 10 z
tor) – NE (female) (3) ance
6
cuit) – NE (female) (3) and chassis ground ance 100 kz
ness Wiring harness between CE01 (female) (27)
Voltage Max. 1 V
– NE (female) (3) and chassis ground

Wiring harness between CE01 (female) (27)
– NE (female) (3) and between CE01
8 ness ance 100 kz
(female) (16) – NE (female) (1)
Resist- Min.
Possible causes – NE (female) (3) and between CE01
ance 100 kz
and standard (female) (48) – NE (female) (2)
value in normal Connecting parts between engine Ne speed sensor – engine wiring
state harness – engine controller may be defective. Check them directly.
connector
CE01 Voltage
Circuit diagram related to engine Ne speed sensor
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor
trouble
Action of
• Controls the engine with signal from engine Ne speed sensor.
controller
Problem that • Engine does not start at all or does not start easily.
appears on • Idle speed is unstable.
machine • Exhaust gas becomes black.
Related
information

Breakage of engine Ne
1 Engine Ne speed sensor may be broken. Check it directly.
speed sensor
Breakage of engine Bkup
2 Engine Bkup speed sensor may be broken. Check it directly.
speed sensor
Rotation sensor wheel on crankshaft side may be installed defec-
tively or broken. Check it according to the following procedure.
Defective installation or
1) Set No. 1 cylinder at compression top dead centre
3 breakage of rotation sensor
(Match stamped mark).
wheel on crankshaft side
2) If centre of oblong hole of rotation sensor wheel is at tip of Ne
speed sensor, rotation sensor wheel is installed normally.
Possible causes Rotation sensor ring on camshaft side may be installed defectively
and standard or broken. Check it according to the following procedure.
value in normal Defective installation or 1) Set No. 1 cylinder at compression top dead centre
state 4 breakage of rotation sensor (Match stamped mark).
ring on camshaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 crest) of rotation sensor ring are seen through
sensor mounting hole, rotation sensor ring is installed normally.
Defective timing of crank- Timing of crankshaft and camshaft may be defective. Check it
5
shaft and camshaft directly.
Ground terminal may be connected defectively. Check following ter-
minals directly.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
6
ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
Failure code [CA757] All Persistent Data Lost Error 1
Action code Failure code All persistent data lost error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
• Engine may stop and may not be started again.
appears on
• Monitoring function of machine monitor (engine controller system) may not work normally.
machine
Related
information

Looseness or corrosion of
2 Battery terminal may be loosened or corroded. Check it directly.
battery terminal
a Prepare with starting switch OFF, then keep starting switch
OFF and turn it to START and carry out troubleshooting in
each case.
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
4 Defective fuse No. 19 If fuse is broken, circuit probably has ground fault.
Possible causes this time, replaced relay is defective.
and standard
value in normal
state
Disconnection in wiring har- Wiring harness between F01-19 – R23, R24 Resist-
ness Max. 10 z
(female) (3) ance
defective contact in connec- Wiring harness between R23, R24 (female) Resist-
Max. 10 z
tor) (5) – CE03 (female) (3) ance
Wiring harness between CE03 (female) (1) – Resist-
Max. 10 z
chassis ground (T11) ance
Connecting parts between fuse No. 19 – machine wiring harness –
connector
and start engine and carry out troubleshooting in each case.
8 Defective engine controller CE03 (female) Starting switch Voltage
ON Min. 24 V
Between (3) – (1)
START Min. 12 V
Failure code [CA778] Eng Bkup Speed Sensor Error 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
• There is error in signal from engine Bkup speed sensor.
trouble
Action of
• Continues control with signal from engine Ne speed sensor.
controller
Problem that
appears on
machine
Related
information

1
G (male) Voltage
Defective engine Bkup
speed sensor
Breakage or improper clear-
Engine Bkup speed sensor may be broken or may have improper
3 ance of engine Bkup speed
clearance. Check it directly.
sensor
Breakage of rotation sensor
4 Rotation sensor ring may be broken. Check it directly.
ring
value in normal defective contact in connec- Wiring harness between CE01 (female) (26) Resist- Max. 10 z
state tor) – G (female) (3) ance
6
cuit) – G (female) (3) and chassis ground ance 100 kz
ness Wiring harness between CE01 (female) (26)
Voltage Max. 1 V
– G (female) (3) and chassis ground
– G (female) (3) and between CE01 (female)
8 ness ance 100 kz
(37) – G (female) (1)
Resist- Min.
– G (female) (3) and between CE01 (female)
ance 100 kz
(47) – G (female) (2)

Connecting parts between engine Bkup speed sensor – engine wir-
9
Possible causes connector • Looseness of connector, breakage of lock, or breakage of seal
and standard • Corrosion, bend, breakage, push-in, or expansion of pin
value in normal • Moisture or dirt in connector or defective insulation
state
CE01 Voltage
Circuit diagram related to engine Bkup speed sensor
Failure code [CA1228] EGR valve servo error 1 1

Action code Failure code EGR valve servo error 1
Trouble
Contents of
• There is servo error (level 1) of EGR valve.
trouble
Action of • Performs open control.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on —
machine
Related
information

a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is not normal, carry out troubleshooting (S-
and standard mode) for mechanical system. (S-12 Oil pressure drops)
value in normal Defective EGR valve oil Oil pump or relief valve for EGR valve circuit may be defective.
state 3
pump Check it directly.
Defective EGR valve oil Oil pressure supply piping for EGR valve circuit may be defective.
4
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
5
pressure return piping Check it directly.
6 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
If causes 1 – 6 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)
Failure code [CA1625] EGR valve servo error 2 1

Action code Failure code EGR valve servo error 2
Trouble
Contents of
• There is servo error (level 2) of EGR valve.
trouble
Action of
• Close EGR and bypass valves.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
machine
Related
information

and standard
state
Failure code [CA1633] KOMNET Datalink Timeout Error 1
Action code Failure code KOMNET Datalink timeout error

Trouble
E0E CA1633 (Engine controller system)
Contents of • Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of • Continues operation in default mode.
Problem that
• Information may not transmitted normally by KOMNET communication and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed section.)
machine
Related
information

a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resist-
ness (Disconnection in wiring (9) – CP01 (female) (45), – CE02 (female) Max. 1 z
1 ance
or defective contact in con- (46), – K02 (female) (A)
nector) Wiring harness between CM02 (female) (10)
Resist-
– CP01 (female) (64), – CE02 (female) (47), Max. 1 z
ance
– K02 (female) (B)
Wiring harness between CM02 (female) (8),
Ground fault in wiring har- Resist-
(9) – CP01 (female) (45), – CE02 (female) Min. 1 Mz
2 ness (Short circuit with GND ance
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female) (10)
and standard Resist-
– CP01 (female) (64), – CE02 (female) (47), Min. 1 Mz
value in normal ance
– K02 (female) (B), – N08 (male) (10)
state
Max.
Hot short (Short circuit with (9) – CP01 (female) (45), – CE02 (female) Voltage
3 5.5 V
24V circuit) in wiring harness (46), – K02 (female) (A), – N08 (male) (3)
Wiring harness between CM02 (female) (10)
Max.
– CP01 (female) (64), – CE02 (female) (47), Voltage
5.5 V
– K02 (female) (B), – N08 (male) (10)
Defective CAN terminal without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 z
If causes 1 – 4 are not detected, engine controller may be defective.
5 Defective pump controller
Circuit diagram related to KOMNET communication
Failure code [CA2185] Throt Sens Sup Volt High Error 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Between CE02 (female) (22) – each of CE02 Resist- Min.
1 ness
(female) pins (With P20 disconnected) ance 100 kz
Possible causes Between CE02 (female) (22) – CE03 Resist- Min.
and standard (female) (3) (With P20 disconnected) ance 100 kz
value in normal Connecting parts between fuel control dial – machine wiring har-
state ness – engine controller may be defective. Check them directly.
connector
out.)
Failure code [CA2186] Throt Sens Sup Volt Low Error 1
Action code Failure code Throttle sensor supply voltage low error
Trouble
Contents of
• Low voltage was detected in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

1
cuit) – P20 (female) (1) and chassis ground ance 100 kz
Possible causes 2 ness
and standard (with another wiring harness) Between CE02 (female) (9) – each of CE02 Resist- Min.
value in normal (female) pins (With P20 disconnected) ance 100 kz
state Connecting parts between fuel control dial – machine wiring har-
connector
out.)
Failure code [CA2249] Rail Press Very Low Error 1
Action code Failure code Common rail pressure very low error
Trouble
Contents of
• There is low pressure error (2) in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start easily.
appears on • Exhaust gas becomes black.
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
Failure code [CA2271] EGR valve lift sensor high error 1

43
Action code Failure code EGR valve lift sensor high error
Trouble
Contents of
• High voltage is detected in EGR valve lift sensor circuit.
trouble
Action of • Limits output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
supply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective EGR valve lift SEGR Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
Possible causes without turning starting switch ON.
and standard Disconnection in wiring Wiring harness between CE01 (female) (37) Resist-
value in normal Max. 1 z
harness – SEGR (female) (1) ance
state 3
(Disconnection or defective Wiring harness between CE01 (female) (47) Resist-
contact in connector) Max. 1 z
– SEGR (female) (2) ance
Max. 1 z
– SEGR (female) (3), (4) ance
Min. 1 Mz
Ground fault in wiring harness – SEGR (female) (1) and chassis ground ance
4
(Contact with ground circuit) Wiring harness between CE01 (female) (47) Resist-
Min. 1 Mz
– SEGR (female) (2) and chassis ground ance
Min. 1 Mz
– SEGR (female) (3), (4) and chassis ground ance

without turning staring switch ON.
Resist-
– SEGR (female) (1) and CE01 (female) (47) Min. 1 Mz
ance
– SEGR (female) (2)
Short circuit in wiring harness
5
Possible causes (with another wiring harness) Wiring harness between CE01 (female) (37) Resist-
and standard – SEGR (female) (1) and CE01 (female) (19) Min. 1 Mz
ance
value in normal – SEGR (female) (3), (4)
state Wiring harness between CE01 (female) (47)
Resist-
– SEGR (female) (2) and CE01 (female) (19) Min. 1 Mz
ance
– SEGR (female) (3), (4)
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
CE01 Voltage
Between (37) and (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
Failure code [CA2272] EGR valve lift sensor low error 1

Action code Failure code EGR valve lift sensor low error
Trouble
Contents of
• Low voltage is detected in EGR valve lift sensor circuit.
trouble
Problem that
machine
Related
information

and standard
value in normal Carry out trouble shooting for failure code [CA2271].
state
Failure code [CA2351] EGR valve solenoid operation short circuit 1
Action code Failure code EGR valve solenoid operation short circuit error
Trouble
Contents of
• Short circuit was detected in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

Defective EGR valve solenoid without turning starting switch ON.
1
(Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 z
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between CE01 (female) (22) Resist-
2 Max. 1 z
(Disconnection or defective – EGR (female) (1) ance
contact in connector) Wiring harness between CE01 (female) (11) Resist-
Max. 1 z
– EGR (female) (2) ance
Possible causes without turning starting switch ON.
and standard
value in normal Ground fault in wiring harness Wiring harness between CE01 (female) (22) Resist-
3 Min. 1 Mz
state (Contact with ground circuit) – EGR (female) (1) and chassis ground ance
Min. 1 Mz
– EGR (female) (2) and chassis ground ance
Hot short in wiring harness Wiring harness between CE01 (female) (22)
4 Voltage Max. 1 V
(Contact with 24 V circuit) – EGR (female) (1) and chassis ground
Voltage Max. 1 V
– EGR (female) (2) and chassis ground
Between (22) and (11) 10 – 21 z
Circuit diagram related to EGR valve solenoid & lift sensor
Failure code [CA2352] EGR valve solenoid operation disconnect 1
Action code Failure code EGR valve solenoid operation disconnection error
Trouble
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

and standard
value in normal Carry out trouble shooting for failure code [CA2351].
state
Failure code [CA2555] Grid Htr Relay Volt High Error 1
Action code Failure code Grid heater relay volt high error
Trouble
Contents of
• Disconnection was detected in drive circuit of intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below –4°C.

ing without turning starting switch ON. (Troubleshooting for
relay unit)
R18 (male) Resistance
Defective automatic pre- Between (1) – (2) 300 – 600 z
1 heater relay a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection).
and carry out troubleshooting. (Troubleshooting by replace-
ment)
Replace automatic preheater relay (R18) with another relay and
perform reproducing operation. If “E” of failure code goes off at this
time, replaced relay is defective.
ness
Possible causes Wiring harness between CE02 (female) (40) Resist-
and standard 2 (Disconnection in wiring or Max. 10 z
– R18 (female) (1) ance
value in normal
state Max. 10 z
– R18 (female) (2) ance
3 ness
(with another wiring harness) Between CE02 (female) (40) – each of CE02 Resist- Min.
(female) pins (With R18 disconnected) ance 100 kz
Connecting parts between automatic preheater relay – machine wir-
4
Between (40) – (42) 300 – 600 z
Circuit diagram related to preheating, starting and charging engine
Failure code [CA2556] Grid Htr Relay Volt Low Error 1
Action code Failure code Grid heater relay volt low error
Trouble
Contents of
• Short circuit was detected in drive circuit of intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low
appears on
temperature).
machine
Related • Method of reproducing failure code: Turn starting switch ON when engine coolant temperature is
information below –4°C.

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

Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
Problem that
appears on • Engine does not stop.
machine
Related • Operating condition of battery relay (ON/OFF) can be checked with monitoring function.
information Code 03700: Controller Output)

Battery relay Resistance
Defective battery relay
1 Between R02 (terminal BR) –
(Internal defect) There is continuity
R01 (terminal E)
Between R02 (terminal BR) –
Min. 1 Mz
chassis ground
Possible causes
state 2 Wiring harness between CP03 (female) (4) –
cuit) D01 – J01 – R02 (terminal BR) and chassis Min. 1 Mz
ance
ground
Turn starting switch
3 Defective pump controller CP03 (female) Voltage
OFF.
Between (4) – chas- 20 – 30 V
ON o OFF
sis ground (4 – 7 sec.)
Circuit diagram related to battery relay drive
Failure code [DA25KP] 5V sensor power supply output 1 abnormality 1
Action code Failure code 5V sensor power supply output 1 abnormality

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

Bucket DUMP PPC
P01
pressure switch
Boom RAISE PPC
P03
pressure switch
Disconnect sensors at right in Bucket CURL PPC
Defective pressure sensor order and carry out operation to P04
1 pressure switch
(Internal short circuit) reproduce trouble. If "E" of failure
Arm IN PPC
code goes off when a sensor is P05
pressure switch
disconnected, that sensor is
defective. Swing RIGHT PPC
P07
pressure switch
Swing LEFT PPC
P08
pressure switch
Pump pressure sensor P25
and standard ing without turning starting switch ON.
value in normal Wiring harness between CP01 (female) (34)
state – P01 (female) (2), P01 (female) (1) – J03 – Resist-
Min. 1 Mz
ground (T08) ance
[Bucket DUMP PPC pressure switch system]
Wiring harness between CP01 (female) (53)
– P03 (female) (2), P03 (female) (1) – J03 – Resist-
Min. 1 Mz
ground (T08) ance
[Boom RAISE PPC pressure switch system]
2 ness (Short circuit with GND Wiring harness between CP01 (female) (73)
circuit) – P04 (female) (2), P04 (female) (1) – J03 – Resist-
Min. 1 Mz
ground (T08) ance
[Bucket CURL PPC pressure switch system]
Min. 1 Mz
ground (T08) ance
[Arm IN PPC pressure switch system]
Min. 1 Mz
ground (T08) ance
[Swig RIGHT PPC pressure switch system]

Min. 1 Mz
Ground fault in wiring har- ground (T08) ance
2 ness (Short circuit with GND [Swing LEFT PPC pressure switch system]
circuit) Wiring harness between CP01 (female) (9) –
Resist-
J07 – P25 female (3) Min. 1 Mz
ance
[Pump pressure sensor system]
– P01 (female) (2), P01 (female) (1) – J03 –
Voltage Max. 1 V
ground (T08)
[Bucket CURL PPC pressure sensor system]
Voltage Max. 1 V
ground (T08)
[Swing LEFT PPC pressure sensor system]
Possible causes Wiring harness between CP01 (female) (73)
and standard – P04 (female) (2), P04 (female) (1) – J03 –
value in normal Voltage Max. 1 V
ground (T08)
state [Arm IN PPC pressure sensor system]
Hot short (Short circuit with
3 24 V circuit) in wiring har- Wiring harness between CP01 (female) (17)
ness – P05 (female) (2), P05 (female) (1) – J03 –
ground (T08) Voltage Max. 1 V
[Bucket DUMP PPC pressure sensor sys-
tem]
Voltage Max. 1 V
ground (T08)
[Boom RAISE PPC pressure sensor system]
Voltage Max. 1 V
ground (T08)
[Swing RIGHT PPC pressure sensor system]
Wiring harness between CP01 (female) (9) –
J07 – P25 (female) (3) Voltage Max. 1 V
[Pump pressure sensor system]
If causes 1 – 3 are not detected, pump controller may be defective.
Circuit diagram related to pressure sensor power supply of pump controller
Failure code [DA2RMC] Pump Comm. Abnormality 1
Action code Failure code Pump communication abnormality

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

ness
Wiring harness between CM02 (female) (10) Resist-
– CE02 (female) (47), – CP01 (female) (64) ance
tor) Wiring harness between CM02 (female) (9) – Resist-
Max. 1 z
CE02 (female) (46), – CP01 (female) (45) ance
Ground fault in wiring har- Wiring harness between CM02 (female) (10)
Resist-
ness – CE02 (female) (47), – CP01 (female) (68), Min. 1 Mz
2 ance
(Short circuit with GND cir- – other related circuit and chassis ground
cuit)
Resist-
Possible causes – CE02 (female) (46), – CP01 (female) (45), Min. 1 Mz
ance
and standard – other related circuit and chassis ground
state and carry out troubleshooting.
Hot short (Short circuit with – CE02 (female) (47), – CP01 (female) (64), Voltage Max. 1 V
3
24V circuit) in wiring harness – other related circuit and chassis ground
Wiring harness between CM02 (female) (9) –
CE02 (female) (46), – CP01 (female) (45), – Voltage Max. 1 V
other related circuit and chassis ground
Defective CAN terminal ing without turning starting switch ON.
4
resistance K02 (male) Resistance
Between (A) – (B) 40 – 80 z
Defective machine monitor, If causes 1 – 4 are not detected, machine monitor, engine controller,
5 engine controller, or pump or pump controller may be defective. (Since trouble is in system,
controller troubleshooting cannot be carried out.)
Circuit diagram related to CAN communication of pump controller
Failure code [DA2SKQ] Model Selection Abnormality 1
Action code Failure code Model selection abnormality

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

Defective model selection ing without turning starting switch ON.
connector S30 (female) Resistance
1
(Internal disconnection or
short circuit) Between (1), (2), (3), (7) – (8) Max. 1 z
Between (5), (6) – (8) Min. 1 Mz
Wiring harness between CP01 (female) (58) Resist-
Max. 1 z
– S30 (male) (4) and chassis ground ance
Disconnection in wiring har- Max. 1 z
– S30 (male) (3) ance
ness
tor) Wiring harness between CP01 (female) (40) Resist-
Max. 1 z
Possible causes
and standard Wiring harness between CP01 (female) (39) Resist-
Max. 1 z
value in normal – S30 (male) (7) ance
state Wiring harness between S30 (male) (8) – Resist-
Max. 1 z
J05 – chassis ground ance
Ground fault in wiring har- Wiring harness between CP01 (female) (58) Resist-
Min. 1 Mz
ness – S30 (male) (4) and chassis ground ance
3
(Short circuit with GND cir- Wiring harness between CP01 (female) (39) Resist-
cuit) Min. 1 Mz
Min. 1 Mz
CP01 Voltage
4 Defective pump controller Between (21), (39), (44), (58) –
20 – 30 V
chassis ground
Between (21), (39) (77) – chassis
Max. 1 V
ground
Circuit diagram related to model selection connector of pump controller
UEN02649-00

© 2007 KOMATSU
All Rights Reserved
64
UEN02650-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Failure code [DA2RMC] CAN discon (Pump con detected)............................................................................ 4
Failure code [DHPAMA] F Pump Press Sensor Abnormality .......................................................................... 6
Failure code [DHPBMA] R Pump Press Sensor Abnormality ......................................................................... 8
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality ............................................................................ 10
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.......................................................... 12
Failure code [DW43KA] Travel Speed Sol. Disc. .......................................................................................... 14
Failure code [DW43KB] Travel Speed Sol. S/C ............................................................................................ 16
Failure code [DW45KA] Swing Brake Sol. Disc. ........................................................................................... 18
Failure code [DW45KB] Swing Brake Sol. S/C ............................................................................................. 22
Failure code [DW91KA] Travel Junction Sol. Disc. ....................................................................................... 24
Failure code [DW91KB] Travel Junction Sol. S/C ......................................................................................... 26
Failure code [DWJ0KA] Merge-divider Sol. Disc .......................................................................................... 28
Failure code [DWJ0KB] Merge-divider Sol. S/C ........................................................................................... 30
Failure code [DWK0KA] 2-stage Relief Sol. Disc.......................................................................................... 32
Failure code [DWK0KB] 2-stage Relief Sol. S/C........................................................................................... 34

Failure code [DXA0KA] PC-EPC Sol. Disc. .................................................................................................. 36
Failure code [DXA0KB] PC-EPC Sol. S/C .................................................................................................... 38
Failure code [DXE0KA] LS-EPC Sol. Disc. ................................................................................................... 40
Failure code [DXE0KB] LS-EPC Sol. S/C ..................................................................................................... 42
Failure code [DXE4KA] Service Current EPC Disc....................................................................................... 44
Failure code [DXE4KB] Service Current EPC S/C........................................................................................ 45
Failure code [DY20KA] Wiper Working Abnormality ..................................................................................... 46
Failure code [DY20MA] Wiper Parking Abnormality ..................................................................................... 48
Failure code [DY2CKB] Washer Drive Short................................................................................................. 50
Failure code [DY2DKB] Wiper Drive (For) Short........................................................................................... 52
Failure code [DY2EKB] Wiper Drive (Rev) Short .......................................................................................... 54
Failure code [DA2RMC] CAN discon (Pump con detected) 1
Action code Failure code CAN disconnection (Pump controller detected)

Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine mon-
trouble itor and engine controller.
Action of • Continues operation with information of CAN communication just before detection of error.
Problem that
• Information may not transmitted normally by CAN communication and machine may not operate nor-
appears on
mally. (Trouble phenomenon depends on failed section.)
machine
Related
information

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resist-
ness (Disconnection in wiring (9) – CP01 (female) (45), – CE02 (female) Max. 1 z
1 ance
or defective contact in con- (46), – K02 (female) (A)
nector)
Resist-
– CP01 (female) (64), – CE02 (female) (47), Max. 1 z
ance
– K02 (female) (B)
Ground fault in wiring har- Resist-
(9) – CP01 (female) (45), – CE02 (female) Min. 1 Mz
2 ness (Short circuit with GND ance
(46), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female) (10)
and standard Resist-
– CP01 (female) (64), – CE02 (female) (47), Min. 1 Mz
value in normal ance
– K02 (female) (B), – N08 (male) (10)
state
Max.
Hot short (Short circuit with (9) – CP01 (female) (45), – CE02 (female) Voltage
3 5.5 V
24V circuit) in wiring harness (46), – K02 (female) (A), – N08 (male) (3)
Max.
– CP01 (female) (64), – CE02 (female) (47), Voltage
5.5 V
– K02 (female) (B), – N08 (male) (10)
Defective CAN terminal ing without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12 z
If causes 1 – 4 are not detected, pump controller may be defective.
Circuit diagram related to CAN communication of machine monitor
Failure code [DHPAMA] F Pump Press Sensor Abnormality 1
Action code Failure code F pump press sensor abnormality

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

Defective sensor power sup- If failure code [DA25KP] is also displayed, carry out troubleshooting
1
ply system for it first.
Defective F pump pressure
2 sensor P25 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
Disconnection in wiring har- Wiring harness between CP01 (female) (9) – Resist-
ness Max. 1 z
defective contact in connec- Wiring harness between CP01 (female) (18) Resist-
Max. 1 z
tor) – P25 (female) (1) ance
Possible causes
and standard Max. 1 z
– P25 (female) (2) ance
value in normal
state Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
4
cuit) Min. 1 Mz
– P25 (female) (2) and chassis ground ance
Hot short (Short circuit with Wiring harness between CP01 (female) (9) –
5 Voltage Max. 1 V
24V circuit) in wiring harness P25 (female) (3) and chassis ground
Voltage Max. 1 V
– P25 (female) (2) and chassis ground
6 Defective pump controller CP01 Voltage
Between (9) – (18) 4.5 – 5.5 V
Between (49) – (18) 0.5 – 4.5 V
Circuit diagram related to F pump pressure sensor of pump controller
Failure code [DHPBMA] R Pump Press Sensor Abnormality 1
Action code Failure code R pump pressure sensor abnormality

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

1
Defective R pump pressure
2 sensor P26 Voltage
(Internal defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
Max. 1 z
Possible causes
value in normal
4
cuit) Min. 1 Mz
5 Voltage Max. 1 V
Voltage Max. 1 V
Between (9) – (18) 4.5 – 5.5 V
Between (68) – (18) 0.5 – 4.5 V
Circuit diagram related to R pump pressure sensor of pump controller
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality 1
Action code Failure code Arm IN PPC pressure sensor abnormality

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

1
Defective arm IN PPC pres- P04 Voltage
2
sure sensor (Internal defect)
Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
Max. 1 z
Possible causes
value in normal
4
(Short circuit with GND cir- Wiring harness between P04 (female) (17) – Resist-
cuit) Min. 1 Mz
P01 (female) (2) and chassis ground ance
5 Voltage Max. 1 V
Voltage Max. 1 V
Between (9) – (18) 4.5 – 5.5 V
Between (17) – (18) 0.5 – 4.5 V
Circuit diagram related to arm IN PPC pressure sensor of pump controller
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 1
Action code Failure code Bucket CURL PPC press sensor abnormality
Trouble
— DHS4MA (Pump controller system)
Contents of
• Signal voltage from bucket curl PPC pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • Fixes bucket curl PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
machine
information • Input from bucket curl PPC pressure sensor (pressure) can be checked with monitoring function.
(Code 07300: Bucket Curl PPC pressure)

1
Defective bucket curl PPC
2 pressure sensor (Internal P01 Voltage
defect) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness Max. 1 z
Max. 1 z
Possible causes
value in normal
4
cuit) Min. 1 Mz
5 Voltage Max. 1 V
Voltage Max. 1 V
Between (9) – (18) 4.5 – 5.5 V
Between (73) – (18) 0.5 – 4.5 V
Circuit diagram related to bucket curl PPC pressure sensor of pump controller
Failure code [DW43KA] Travel Speed Sol. Disc. 1
Action code Failure code Travel speed solenoid disconnection

Trouble
— DW43KA (Pump controller system)
Contents of
• No current flows at output to travel speed solenoid circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
appears on • Travel speed does not change to Hi. (Machine monitor changes to the normal state.)
machine
• Operating condition of travel speed solenoid (ON/OFF) can be checked with monitoring function.
(Code 02300: Solenoid 1)
Related
• Solenoid detects disconnection when output is turned on. To confirm the reproduction after repair, be
information
sure to turn output on. (For more information on how to turn output on/off, see troubleshooting for
failure code [DW43KB].)

Defective travel speed sole- ing without turning starting switch ON.
1
noid (Internal disconnection) V04 (male) Resistance
Between (1) – (2) 20 – 60 z
ness
– V04 (female) (2) ance
and standard defective contact in connec-
value in normal tor) Wiring harness between V04 (female) (1) – Resist-
Max. 1 z
state chassis ground ance
3
24V circuit) in wiring harness Wiring harness between CP02 (female) (87)
Voltage Max. 1 V
– V04 (female) (2) and chassis ground
CP02 (female) Resistance
Between (87) – chassis ground 20 – 60 z
Circuit diagram related to travel speed solenoid of pump controller
Failure code [DW43KB] Travel Speed Sol. S/C 1
Action code Failure code Travel speed solenoid short

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

Defective travel speed sole-
1 noid (Internal short circuit or V04 (male) Resistance
ground fault) Between (1) – (2) 20 – 60 z
Between (2) – chassis ground Min. 1 Mz
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP02 (female) (87) Resist-
cuit) Min. 1 Mz
– V04 (female) (2) and chassis ground ance
3 Defective pump controller CP02 Travel speed Voltage
Between (87) – chas- Lo Max. 1 V
sis ground Hi + Travel operation 20 – 30 V
Circuit diagram related to travel speed solenoid of pump controller
Failure code [DW45KA] Swing Brake Sol. Disc. 1
Action code Failure code Swing holding brake solenoid disconnection

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

Defective swing holding ing without turning starting switch ON.
1 brake solenoid (Internal dis-
V05 (male) Resistance
connection)
Between (1) – (2) 20 – 60 z
Defective swing lock switch S04 (female) Switch Resistance
2
OFF Max. 1 z
Between (3) – (4)
LOCK Min. 1 Mz
Possible causes
value in normal Defective assembled-type ing without turning starting switch ON.
state 3 diode D01
D01 (male) Digital circuit tester Continuity
Between (7) – (3) Diode mode There is continuity
Wiring harness between CP02 (female) Resist-
(101) – D01 (female) (7) ance
ness
Wiring harness between D01 (female) (3) – Resist-
J02 – S04 (male) (3) ance
tor) Wiring harness between S04 (male) (4) – Resist-
Max. 1 z
V05 (female) (2) ance
Wiring harness between V05 (female) (1) – Resist-
Max. 1 z
CP02 (female) (115), (117), (120) ance

Wiring harness between CP02 (female)
5 (101) – D01 – H15 – S04 (male) (3) and Voltage Max. 1 V
24V circuit) in wiring harness
Possible causes chassis ground
and standard Wiring harness between V05 (female) (2) –
value in normal Voltage Max. 1 V
H15 – S04 (male) (4) and chassis ground
state
6 Defective pump controller CP02 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (101) – (7) on female side 20 – 60 z
chassis ground directly.
Circuit diagram related to swing holding brake solenoid of pump controller
Failure code [DW45KB] Swing Brake Sol. S/C 1
Action code Failure code Swing holding brake solenoid short

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

Defective swing holding
1 brake solenoid (Internal short V05 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60 z
Defective assembled-type ing without turning starting switch ON.
2 diode D01
D01 (male) Resistance
(Internal short circuit)
Possible causes Between (3) – (7) Min. 1 Mz
value in normal
state Ground fault in wiring har-
Wiring harness between CP02 (female)
ness Resist-
3 (101) – D01 – J02 – H15 – S04 (male) (3) Min. 1 Mz
(Short circuit with GND cir- ance
and chassis ground
cuit)
Wiring harness between V05 (female) (2) – Resist-
Min. 1 Mz
H15 – S04 (male) (4) and chassis ground ance
4 Defective pump controller CP02 Swing lever Voltage
Between (101) – At neutral Max. 1 V
chassis ground At swing 20 – 30 V
Circuit diagram related to swing holding brake solenoid of pump controller
Failure code [DW91KA] Travel Junction Sol. Disc. 1
Action code Failure code Travel junction solenoid disconnection

Trouble
— DW91KA (Pump controller system)
Contents of
• No current flows at output to travel junction solenoid circuit.
trouble
Problem that
appears on • Hard to turn when operating travel steering.
machine
• Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
Related
information

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

Trouble
— DW91KB (Pump controller system)
Contents of
• Abnormal current flowed at output to travel junction solenoid circuit.
trouble
Action of • Turns output to travel junction solenoid OFF.
Problem that
appears on • Hard to turn when operating travel steering.
machine
Related • Operating condition of travel junction solenoid (ON/OFF) can be checked with monitoring function.
information Code 02300: Solenoid 1)

Defective travel junction ing without turning starting switch ON.
solenoid V02 (male) Resistance
1
(Internal short circuit or
Possible causes
and standard
value in normal 2
state (Short circuit with GND cir- Wiring harness between CP02 (female) Resist-
cuit) Min. 1 Mz
(110) – V02 (female) (2) and chassis ground ance
3 Defective pump controller CP02 Travel lever Voltage
Between (110) – At straight-travel Max. 1 V
(115), (117), (120) At steering 20 – 30 V
Circuit diagram related to travel junction solenoid of pump controller
Failure code [DWJ0KA] Merge-divider Sol. Disc 1
Action code Failure code Merge-divider solenoid disconnection

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

Defective merge-divider ing without turning starting switch ON.
1 solenoid
Between (1) – (2) 20 – 60 z
ness Wiring harness between CP02 (female) Resist-
Max. 1 z
2 (Disconnection in wiring or (112) – V03 (female) (2) ance
tor) Resist-
value in normal CP02 (female) (115), (117), (120) and chas- Max. 1 z
ance
state sis ground
3
Voltage Max. 1 V
Between (112) – (115), (117),
20 – 60 z
(120)
Circuit diagram related to merge-divider solenoid of pump controller
Failure code [DWJ0KB] Merge-divider Sol. S/C 1
Action code Failure code Merge-divider solenoid short

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

Defective merge-divider ing without turning starting switch ON.
1
Possible causes Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness ing without turning starting switch ON.
value in normal 2
(Short circuit with GND cir- Wiring harness between CP02 (female) Resist-
state cuit) Min. 1 Mz
(112) – V03 (female) (2) and chassis ground ance
CP02 Travel lever Voltage
At neutral Max. 1 V
Between (112) –
(115), (117), (120) When either side is
20 – 30 V
operated
Circuit diagram related to merge-divider solenoid of pump controller
Failure code [DWK0KA] 2-stage Relief Sol. Disc. 1
Action code Failure code 2-stage relief solenoid disconnection

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

Defective 2-stage relief sole- ing without turning starting switch ON.
1 noid
Between (1) – (2) 20 – 60 z
ness
Wiring harness between CP02 (female) Resist-
(109) – V08 (female) (2) ance
and standard defective contact in connec-
value in normal tor) Wiring harness between V08 (female) (1) – Resist-
Max. 1 z
state CP02 (female) (115), (117), (120) ance
3
Voltage Max. 1 V
Between (109) – chassis ground 20 – 60 z
Circuit diagram related to 2-stage relief solenoid of pump controller
Failure code [DWK0KB] 2-stage Relief Sol. S/C 1
Action code Failure code 2-stage relief solenoid short

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

Defective 2-stage relief sole- ing without turning starting switch ON.
noid V08 (male) Resistance
1
Possible causes
and standard 2
value in normal (Short circuit with GND cir- Wiring harness between CP02 (female) Resist-
cuit) Min. 1 Mz
state (109) – V08 (female) (2) and chassis ground ance
CP02 Working mode Voltage
3 Defective pump controller When L-mode is not
Max. 1 V
Between (109) – selected
chassis ground When L-mode is
20 – 30 V
selected
Circuit diagram related to 2-stage relief solenoid of pump controller
Failure code [DXA0KA] PC-EPC Sol. Disc. 1
Action code Failure code PC-EPC solenoid disconnection

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

Defective PC-EPC solenoid ing without turning starting switch ON.
1
(Internal disconnection) V11 (male) Resistance
Between (1) – (2) 7 – 14 z
S21 Switch Resistance
Defective emergency pump
2 drive switch (Internal discon- OFF Max. 1 z
Between (2) – (3)
nection) ON Min. 1 Mz
OFF Max. 1 z
Between (5) – (6)
ON Min. 1 Mz
Possible causes Wiring harness between CP02 (female) (96) Resist-
and standard – S21 (3) ance
Wiring harness between S21 (2) – V11 Resist-
state 3 (Disconnection in wiring or Max. 1 z
(female) (1) ance
tor) Wiring harness between CP02 (female) Resist-
Max. 1 z
(115), (117), (120) – chassis ground ance
Wiring harness between S21 (5) – V11 Resist-
Max. 1 z
(female) (2) ance
Hot short (Short circuit with Wiring harness between CP02 (female) (96)
4 Voltage Max. 1 V
24V circuit) in wiring harness – S21 (3) and chassis ground
Wiring harness between S21 (2) – V11
Voltage Max. 1 V
(female) (1) and chassis ground
Between (96) – (115), (117),
7 – 14 z
(120)
Circuit diagram related to LS-EPC and PC-EPC solenoids of pump controller
Failure code [DXA0KB] PC-EPC Sol. S/C 1
Action code Failure code PC-EPC solenoid short

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

Defective PC-EPC solenoid
1 (Internal short circuit or V11 (male) Resistance
value in normal 2
– S21 – V11 (female) (1) and chassis ground ance
Between (96) – (115), (117),
7 – 14 z
(120)
Failure code [DXE0KA] LS-EPC Sol. Disc. 1
Action code Failure code LS-EPC solenoid disconnection

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

Defective LS-EPC solenoid ing without turning starting switch ON.
1
(Internal disconnection) V19 (male) Resistance
Between (1) – (2) 7 – 14 z
ness Max. 1 z
V19 (female) (1) ance
Possible causes defective contact in connec- Wiring harness between CP02 (female) Resist-
Max. 1 z
and standard tor) (115), (117), (120) – J05 and chassis ground ance
value in normal Wiring harness between S21 (6) – V19 Resist-
state Max. 1 z
(female) (2) ance
3
Voltage Max. 1 V
Between (88) – (115), (117),
7 – 14 z
(120)
Failure code [DXE0KB] LS-EPC Sol. S/C 1
Action code Failure code LS-EPC solenoid short

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

Defective LS-EPC solenoid
1 (Internal short circuit or V19 (male) Resistance
value in normal 2
Between (88) – (115), (117),
7 – 14 z
(120)
Failure code [DXE4KA] Service Current EPC Disc. 1
Action code Failure code Service current EPC solenoid disconnection

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

Defective service current ing without turning starting switch ON.
1 EPC solenoid (Internal dis-
connection)
Between (1) – (2) 7 – 14 z
ness
Possible causes – V30 (female) (1) ance
and standard tor) Wiring harness between CP02 (female) Resist-
(115), (117), (120) – V30 (female) (2) ance
state
2
Voltage Max. 1 V
Between (97) – (115), (117),
7 – 14 z
(120)
Circuit diagram related to service current EPC solenoid of pump controller
Failure code [DXE4KB] Service Current EPC S/C 1
Action code Failure code Service current EPC solenoid short

Trouble
— DXE4KB (Pump controller system)
Contents of
• Abnormal current flowed to service current EPC solenoid circuit.
trouble
Action of • Sets output to service current EPC solenoid circuit to 0.
Problem that
appears on • Attachment does not move.
machine
• Carry out troubleshooting only for setting with ATT. (Confirm settings on the monitor panel.)
Related
• Output to service current EPC solenoid (current value) can be checked with monitoring function.
information
(Code 01700: Service solenoid current)

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

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

M05 (female) Wiper blade Resistance
Defective wiper motor (Inter-
1 Operating range top Max. 1 z
nal disconnection)
Between (6) – (5) Other than operating
Min. 1 Mz
range top
Between (1) – (3) All range Max. 20 z
Disconnection in wiring har- – M05 (male) (6) ance
and standard
value in normal ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resist-
2 Max. 1 z
state or defective contact in con- J04 – chassis ground (T05, T06) ance
nector) Wiring harness between CP02 (female) (114) Resist-
Max. 1 z
– M05 (male) (1) ance
Max. 1 z
CP01 (female) Wiper blade Resistance
3 Defective pump controller Operating range top Max. 1 z
sis ground Other than operating
Min. 1 Mz
range top
Circuit diagram related to wiper motor of machine monitor
Failure code [DY20MA] Wiper Parking Abnormality 1
Action code Failure code Wiper parking abnormality

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

Defective wiper motor (Inter- M05 (female) Wiper blade Resistance

1
nal disconnection) Storage area Max. 1 z
Between (4) – (5)
Working area Min. 1 Mz
Disconnection in wiring har- – M05 (male) (4) ance
and standard
value in normal ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resist-
3 Max. 1 z
state or defective contact in con- J04 – chassis ground (T05, T06) ance
nector) Wiring harness between CP02 (female) (114) Resist-
Max. 1 z
Max. 1 z
CP01 (female) Wiper blade Resistance
Between (75) – chas- Storage area Max. 1 z
sis ground Working area Min. 1 Mz
Failure code [DY2CKB] Washer Drive Short 1
Action code Failure code Window washer drive system short

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

Defective washer motor without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Possible causes Between (1) – (2) 5 – 20 z
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal and carry out troubleshooting.
state 2
24V circuit) in wiring harness Wiring harness between CP01 (female) (3) –
Voltage Max. 1 V
J04 – M6 (female) (2), – D02 (female) (7)
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
Circuit diagram related to window washer motor of machine monitor
Failure code [DY2DKB] Wiper Drive (For) Short 1
Action code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Pump controller system)
Contents of
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive forward side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
information

1 nal short circuit or ground M05 (female) Resistance
fault) Between (3) – (1) There is continuity
Possible causes
and standard Between (3) – chassis ground Min. 1 Mz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring har- without turning starting switch ON.
2 ness (Short circuit with GND
circuit) Wiring harness between CP02 (female) Resist-
Min. 1 Mz
(119) – M05 (male) (3) ance
out.)
Failure code [DY2EKB] Wiper Drive (Rev) Short 1
Action code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Pump controller system)
Contents of
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive reverse side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
information

1 nal short circuit or ground M05 (female) Continuity/Resistance
fault) Between (1) – (3) There is continuity
Possible causes
and standard Between (1) – chassis ground Min. 1 Mz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring har- without turning starting switch ON.
2 ness (Short circuit with GND
circuit) Wiring harness between CP02 (female) Resist-
Min. 1 Mz
(114) – M05 (male) (1) ance
out.)
UEN02650-00

© 2007 KOMATSU
All Rights Reserved
56
UEN02651-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Troubleshooting of electrical system
(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 4
Information contained in troubleshooting table ............................................................................................... 6
E-1 Engine does not start ............................................................................................................................... 7
E-2 Auto-decelerator does not operate......................................................................................................... 10
E-3 Automatic warming-up system does not operate ................................................................................... 12
E-4 Preheater does not operate.................................................................................................................... 14
E-5 All work equipment, swing, and travel mechanism do not move ............................................................ 16
E-6 Power maximizing function does not operate......................................................................................... 18
E-7 Machine monitor does not display at all ................................................................................................. 20
E-8 Machine monitor does not display some items ...................................................................................... 22
E-9 Contents of display by machine monitor are different from applicable machine .................................... 22
E-10 Fuel level monitor was lighted in red while engine running .................................................................. 23
E-11 Engine coolant temperature gauge does not indicate normally............................................................ 24
E-12 Hydraulic oil temperature gauge does not indicate normally................................................................ 26
E-13 Fuel level gauge does not indicate normally ........................................................................................ 27

E-14 Swing lock monitor does not indicate normally..................................................................................... 28
E-15 When monitor switch is operated, monitor displays nothing................................................................. 30
E-16 Windshield wiper and window washer do not operate.......................................................................... 32
E-17 Machine push-up function does not operate normally.......................................................................... 36
E-18 Monitoring function fails to display “boom raise” normally.................................................................... 38
E-19 Monitoring function fails to display “boom lower” normally ................................................................... 40
E-20 Monitoring function fails to display “arm IN” normally........................................................................... 42
E-21 Monitoring function fails to display “arm OUT” normally....................................................................... 44
E-22 Monitoring function fails to display “bucket CURL” normally ................................................................ 46
E-23 Monitoring function fails to display “bucket DUMP” normally ............................................................... 48
E-24 Monitoring function fails to display “swing” normally ............................................................................ 50
E-25 Monitoring function fails to display “travel” normally............................................................................. 52
E-26 Monitoring function fails to display “travel differential pressure” normally ............................................ 54
E-27 Monitoring function fails to display “service” normally .......................................................................... 56
E-28 KOMTRAX system does not operate normally..................................................................................... 58
E-29 Air conditioner does not operate........................................................................................................... 60
E-30 Travel alarm does not sound or does not stop sounding...................................................................... 62
E-31 Horn does not sound ............................................................................................................................ 64
Before carrying out troubleshooting of electrical system 1

Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is in the ON position and
a constant power supply is a device which supplies power while the starting switch is in the OFF and ON
positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fus-
ible links to see if the power is supplied normally.
Type of power
Fusible link Fuse No. Fuse capacity Destination of power
supply
1 10A Pump controller
2 20A Pump controller (Solenoid power supply)
PPC oil pressure lock solenoid valve
Switch power F04 3 20A Machine monitor
supply (65A) Wiper motor
Cigarette lighter
4 10A
Windshield washer motor
5 10A Horn relay, horn
6 10A Intake air heater
7 10A Rotary lamp
Right headlamp, working lamp (boom), working lamp
Switch power F04 8 10A
(rear)
supply (65A)
Radio
9 10A
Left knob switch (pump controller input)
10 10A (Spare)
Air conditioner unit
11 20A
Air conditioner compressor electromagnetic clutch
12 20A (Spare)
Switch power F04
13 20A Headlamp
supply (65A)
14 10A Optional power supply (1)
Travel alarm
15 10A
Optional power supply (2)
Radio (backup power supply)
16 10A
Room lamp
Constant F05 Starting switch
17 10A
power supply (30A) Machine monitor
18 10A (Spare)
19 30A Engine controller
Switch power Starting switch
20 5A Engine controller (ACC signal)
supply ACC
Location of fuse box and fuse Nos.
Information contained in troubleshooting table 1

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure phe-
Phenomenon occurring on machine
nomenon
Relative infor-
Information on the failure occurred as well as the troubleshooting
mation
<Contents of description>
• Standard value in normal state to judge possible causes
Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is bro-
ken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
V) circuit is in contact with power source (24 V) circuit.
2
• Short circuit
Independent wiring harnesses are in contact with each other
Possible causes abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
state ence numbers, which do not <Precautions for troubleshooting>
indicate priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trouble-
3 shooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”,
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of “male” and “female”, dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram

which shows the portion where the failure
occurred.
• Connector No.: Indicates (Type – numbers of a
pin) (color)
• Arrow : Roughly indicates the location in the
machine where it is installed.
E-1 Engine does not start 1
Trouble • Engine does not start (Engine does not turn).

• Engine starting circuit has following 2 start lock mechanisms:
Related infor- 1) Start lock by the machine monitor password
mation 2) Start lock by the lock lever
• In the case no error code for the engine controller mechanism is indicated

Battery voltage Specific gravity of battery
1 Low charge level of battery
Min. 24 V Min. 1.26
If fuse or fusible link is burnt out, the circuit probably has ground
Defective fuse No. 3, No. 17 fault.
2
or fusible link F04 and F05 In the case the machine monitor does not light up, check the power
circuit between the battery and the fuse.
Defective starting switch H06 (male) Position Resistance
3
OFF Min. 1 Mz
Between (1) – (4)
START Max. 1 z
Defective safety lock switch S14 (female) Lock lever Resistance
4
(internal short circuit)
Free Min. 1 Mz
Between (1) – (3)
Lock Max. 1 z
Possible causes
and standard
value in normal ing without turning starting switch ON.
Defective starting motor cut-
state out relay R06 or R07 (Inter- R06 (male), R07 (male) Resistance
5
nal short circuit or ground Between (1) – (2) 100 – 500 z
fault)
Between (3) – (5) Min. 1 Mz
(If power supply and starting input and output are normal but
starting motor does not turn, starting motor is defective.)
Defective starting motor
Starting
6 (Internal disconnection or Starting motor Voltage
switch
breakage)
Power supply: Between terminal
20 – 30 V
B and chassis ground When
Starting input: Terminal C – chas- started
20 – 30 V
sis ground
Defective alternator or start engine and carry out troubleshooting.
7
(Internal short circuit) Alternator Voltage
Terminal R – chassis ground Max. 1 V

Wiring harness between F01-17 – H06 Resis-
Max. 1 z
(female) (1) tance
Wiring harness between H06 (female) (4) – Resis-
Max. 1 z
J01 – R06 (female) (5) tance
Disconnection in wiring har- Wiring harness between R06 (female) (3) – Resis-
ness Max. 1 z
M17 (female) (1) tance
defective contact in connec- Wiring harness between F01-3 outlet – S14 Resis-
Max. 1 z
tor) (female) (1) tance
Wiring harness between S14 (female) (3) – Resis-
Max. 1 z
R06 (female) (1) tance
Wiring harness between R06 (female) (2) – Resis-
Max. 1 z
R07 (female) (6) tance
Max. 1 z
J04 – chassis ground tance
Possible causes
and standard
value in normal Wiring harness between battery relay termi-
Resis-
state nal B (R04) – F05 – F01-16D and chassis Min. 1 Mz
tance
ground
Wiring harness between F01-17 – H06 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Ground fault in wiring har- Wiring harness between H06 (female) (4) – Resis-
ness Min. 1 Mz
9 J01 – R06 (female) (5) and chassis ground tance
(Short circuit with GND cir-
cuit) Wiring harness between R06 (female) (3) – Resis-
Min. 1 Mz
M17 (female) (1) and chassis ground tance
Wiring harness between F01-3 – S14 Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
Min. 1 Mz
R06 (female) (1) and chassis ground tance
Min. 1 Mz
J05 – P02 (female) (14) and chassis ground tance
10
24V circuit) in wiring harness Wiring harness between P02 (female) (11) –
J02 – M17 (female) (2), – D01 (female) (6), – Voltage Max. 1 V
alternator terminal R and chassis ground
Circuit diagram related to engine start and battery charging
E-2 Auto-decelerator does not operate 1
Trouble • Auto-decelerator does not operate.

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

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

shooting No. E-29.
8 Defective travel signal
Operation of lever:
01900 Travel ON
Possible causes Lever in neutral: OFF
and standard In the case monitoring is not normally indicated, proceed to trouble-
value in normal shooting No. E-30.
state
9 Defective attachment signal
Operation of lever:
01901 Service ON
Since trouble is in system, troubleshooting cannot be carried out.
10 Defective pump controller (If causes 1 – 9 above are not detected, engine controller may be
defective.)
E-3 Automatic warming-up system does not operate 1
Trouble • Automatic warming-up system does not operate

• When engine coolant temperature is below 30°C, automatic warm-up system raises engine speed to
Related infor- 1,250 rpm.
mation • If fuel control dial is opened more than 70% for 3 seconds or longer when starting switch is turned
ON or after engine is started, automatic warm-up system is turned OFF.

shooting No. E-14.
Possible causes Defective engine coolant Monitoring code Item Normal display
1
and standard temperature signal Compare with actual
value in normal Engine coolant tem-
04102 engine coolant tem-
state perature
perature
Since trouble is in system, troubleshooting cannot be carried out. (If
2 Defective pump controller causes stated above are not detected, engine controller may be
defective.)
E-4 Preheater does not operate 1
Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up.
Related infor- Input of preheating signal (ON/OFF) can be checked with monitoring function.
mation (Code 04500: Monitor Input 1)

Defective starting switch sys- If preheating fails to operate (the heater does not warm up), refer to
1
tem Trouble (2)
value in normal defective contact in connec- Wiring harness between P02 (female) (18) – Resis-
Max. 1 z
tor) J02 (male) (7) tance
state
a Prepare with starting switch OFF
P02 Starting switch Voltage
3 Defective machine monitor
Between (18) – chas- OFF Max. 1 V
sis ground HEAT 20 – 30 V
Trouble (2) • When starting switch is turned to HEAT position, preheater does not warm up.
Related infor- • During low temperature (coolant temperature below 30°C), pump controller drives the heater relay
mation for 100 sec. after engine start to automatically preheat.

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

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

• Symbol mark is indicated on the machine monitor when the power maximizing switch is depressed
Related infor- during work equipment operation while the engine is running in P- or E-mode.
mation • Input state of power maximizing switch (left knob switch) can be checked with monitoring function
(Code 02200: Switch Input 1)

Defective power maximizing
2 switch (Internal disconnec- S11(male) Switch Resistance
tion) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
ness
Wiring harness between F01-9 outlet – S11 Resis-
Possible causes (female) (1) tance
and standard tor) Wiring harness between S11 (female) (2) – Resis-
CP01 (female) (11) tance
state
ness Wiring harness between F01-9 outlet – S11 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- (female) (1) and chassis ground tance
cuit)
Min. 1 Mz
CP01 (female) (11) and chassis ground tance
5 Defective pump controller CP01 Switch Voltage
Between (11) – chas- Released Max. 1 V
sis ground Pressed 20 – 30 V
Circuit diagram related to power max. switch
E-7 Machine monitor does not display at all 1
Trouble • Machine monitor does not display at all when starting switch is turned ON
Related infor-
—
mation

ness
Wiring harness between P01(female) (1) (2) Resis-
– J06 – F01-3 outlet tance
tor) Wiring harness between P01 (female) (6), Resis-
Max. 1 z
(7) – chassis ground tance
Possible causes
and standard
value in normal 3
state (Short circuit with GND cir- Wiring harness between P01(female) (1), (2) Resis-
cuit) Min. 1 Mz
– J06 – F01-3 outlet and chassis ground tance
P01 (female) Voltage/Resistance
4 Defective machine monitor Between (1), (2) – chassis
Voltage: 20 – 30 V
ground
Between (6), (7) – chassis
Resistance: Max. 1 z
ground
Circuit diagram related to power source in monitor panel
E-8 Machine monitor does not display some items 1
Trouble • Machine monitor does not display some items when starting switch is turned ON
Related infor-
—
mation

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

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

In the case monitoring display is not normal, proceed to failure code
[DA2SKQ].
Possible causes Defective model code signal Monitoring code Item Normal display
1
and standard (Internal defect) 00200 Controller model
value in normal code 300
state 00201 Select model
2 Defective machine monitor causes stated above are not detected, engine controller may be
defective.)
E-10 Fuel level monitor was lighted in red while engine running 1
Trouble • Fuel level monitor was lighted in red while the engine running
• If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red.
Related infor-
• Input signal (voltage) from the fuel level sensor can be checked with monitoring function.
mation
(Code 04200: Fuel level sensor voltage)

Low fuel level
1 a Add fuel
(When system is normal)
Defective fuel level sensor P21 (male) Fuel level Resistance
2
Between (1) and FULL (Upper limit) Approx. 12 z
Possible causes chassis ground EMPTY (Lower limit) 85 – 110 z
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
state 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between P02 (female) (2) – Resis-
Max. 1 z
tor) P21 (female) (1) tance

4 Defective machine monitor P02 (female) Fuel level Resistance
Between (2) and FULL (Upper limit) Approx. 12 z
chassis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
E-11 Engine coolant temperature gauge does not indicate normally 1
• While engine coolant temperature is rising normally, temperature gauge does not rise from white
Trouble range (C).
• While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H).
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring
Related infor- function. (Code: 04105: Engine coolant temperature)
mation • Check if failure code for abnormal communication (machine monitor) system [DAFRMC] is indicated
(if yes, diagnose that failure first.)

Defective coolant tempera- Engine coolant tem-
ture sensor TWTR (male) Resistance
1 perature
short circuit) Between (A) – (B) 90 – 3.5 kz
Between (A) – chas- 10 – 100°C
Min. 1 Mz
sis ground
ness
Wiring harness between CE01 (female) (15) Resis-
– TWTR (female) (A) tance
Possible causes tor) Wiring harness between TWTR (female) (B) Resis-
Max. 1 z
and standard – chassis ground tance
state ing without turning starting switch ON.
ness
3
(Short circuit with GND cir- Wiring harness between CE01 (female) (15) Resis-
cuit) Min. 1 Mz
– TWTR (female) (A) and chassis ground tance
4
24V circuit) in wiring harness Wiring harness between CE01 (female) (15)
Voltage Max. 1 V
– TWTR (female) (A) and chassis ground
Engine coolant tem-
perature
10 – 100°C 90 – 3.5 kz
sis ground
E-12 Hydraulic oil temperature gauge does not indicate normally 1
• While hydraulic oil temperature is rising normally, temperature gauge does not rise from white range
Trouble (C).
• While hydraulic oil temperature is stabilized normally, temperature gauge rises to red range (H).
Related infor- • Input from the hydraulic oil temperature sensor (temperature) can be checked with monitoring func-
mation tion. (Code 04402: Hydraulic oil temperature)

Defective hydraulic oil tem- Engine coolant tem-
perature sensor P22 (male) Resistance
1 perature
short circuit) Between (1) – (2) 90 – 3.5 kz
Between (2) – chas- 10 – 100°C
Min. 1 Mz
sis ground
ness
Wiring harness between P02 (female) (12) – Resis-
P22 (female) (2) tance
tor) Wiring harness between P02 (female) (13) – Resis-
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
state ness ing without turning starting switch ON.
3
(Short circuit with GND cir- Wiring harness between P02 (female) (12) – Resis-
cuit) Min. 1 Mz
P22 (female) (2) and chassis ground tance
4
Voltage Max. 1 V
P22 (female) (2) and chassis ground
Engine coolant tem-
P02 Resistance
5 Defective machine monitor perature
Between (12) – (13) 90 – 3.5 kz
Between (12) – chas- 10 – 100°C
Min. 1 Mz
sis ground
Circuit diagram related to hydraulic oil temperature sensor
E-13 Fuel level gauge does not indicate normally 1
• While fuel is added, fuel level gauge does not rise from red range (E).
Trouble
• While fuel level is low, fuel level gauge does not lower from green range (F)
Related infor- • Input signal (voltage) from the fuel level sensor can be checked with monitoring function. (Code
mation 04200: Fuel level sensor voltage)

Defective fuel level sensor
1 (Internal disconnection or P21 (male) Fuel level Resistance
short circuit) FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Max. 1 z
tor) P21 (female) (1) tance
Possible causes
and standard Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness ing without turning starting switch ON.
3
state (Short circuit with GND cir- Wiring harness between P02 (female) (2) – Resis-
cuit) Min. 1 Mz
4
Voltage Max. 1 V
P21 (female) (1) and chassis ground
5 Defective machine monitor P02 Fuel level Resistance
Between (2) – chas- FULL (Upper limit) Approx. 12 z
sis ground EMPTY (Lower limit) 85 – 110 z
Circuit diagram related to fuel level sensor
E-14 Swing lock monitor does not indicate normally 1
• When swing lock switch is turned ON, swing lock monitor does not light up.
Trouble
• When swing lock switch is turned OFF, swing lock monitor lights up.
Related infor- • Input from swing lock switch (ON/OFF) can be checked with monitoring function.

Defective swing lock switch
1 (Internal disconnection or S04 (female) Swing lock switch Resistance
short circuit) OFF Min. 1 Mz
Between (1) – (2)
ON Max. 1 z
ness
J02 – S04 (male) (1) tance
tor) Wiring harness between S04 (male) (2) – Resis-
and standard
3
cuit) Min. 1 Mz
J02 – S04 (male) (1) and chassis ground tance
4
Voltage Max. 1 V
J02 – S04 (male) (1) and chassis ground
5 Defective machine monitor P02 Swing lock switch Voltage
Between (17) – chas- OFF 20 – 30 V
sis ground ON Max. 1 V
Circuit diagram related to swing lock switch
E-15 When monitor switch is operated, monitor displays nothing 1
Trouble (1) • Operating the working mode select switch fails to display working mode monitor.
Related infor-
—
mation

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

and standard
state
Trouble (3) • Operating the travel speed select switch fails to display travel speed monitor.
Related infor-
a If travel speed selection fails, proceed with troubleshooting No. H-21.
mation

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

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

Trouble (5) • When LCD monitor adjust switch is operated, adjust screen is not displayed.
• When maintenance switch is operated, maintenance item screen is not displayed.
Related infor-
—
mation

and standard
state
E-16 Windshield wiper and window washer do not operate 1
Trouble • Windshield wiper and window washer do not operate (1) Windshield wiper does not operate.
Related infor- • Input from window limit switch (ON/OFF) can be checked with monitoring function.

Defective swing lock switch W03 (female) Front window Resistance
1 (Internal disconnection or When installed to
short circuit) Min. 1 Mz
front
Between (1) – (2)
When retracted to
Max. 1 z
rear
Defective wiper motor W04 (female) Resistance
2 (Internal disconnection or
short circuit) Between (3) – (1)
Between (3), (1) – chassis
Min. 1 Mz
ground
ness
Possible causes W04 (male) (3) tance
and standard Wiring harness between P01 (female) (10) – Resis-
tor)
W04 (male) (1) tance
state
4
cuit) Min. 1 Mz
W03 (male) (2) and chassis ground tance
Defective machine monitor P02 Front window Voltage
(window limiter switch sys- When installed to
tem) 20 – 30 V
Between (15) – chas- front
sis ground When retracted to
Max. 1 V
rear
5
P02 Wiper switch Voltage
Defective machine monitor
(Wiper motor system) Between (9) – chas- OFF Max. 3 V
sis ground
Between (10) – chas- Max. 3 V ⇔ 20 – 30 V
ON
sis ground (Constant cycle)
Circuit diagram related to windshield wiper motor
Trouble • Windshield wiper and window washer do not operate (2) Window washer does not operate.
Related infor-
mation

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault (See cause 4).
Defective washer motor
2 (Internal disconnection or M06 (male) Resistance
short circuit) Between (1) – (2) 5 – 20 z
ness
Wiring harness between F01-4 – J03 – J06 – Resis-
M06 (female) (1) tance
tor) Wiring harness between M06 (female) (2) – Resis-
J04 – P01 (female) (3) tance
and standard
value in normal
state ing without turning starting switch ON.
Wiring harness between F01-4 – J03 – J06 –
M06 (female) (1), – D02 (female) (4), – other Resis-
ness Min. 1 Mz
4 harnesses between related circuits and tance
chassis ground
cuit)
Wiring harness between M06 (female) (2) –
Resis-
J04 – P01 (female) (3), – D02 (female) (8) Min. 1 Mz
tance
and chassis ground
Defective machine monitor Windshield washer
5 (window limiter switch sys- P01 Voltage
switch
tem)
Between (3) – chas- OFF 20 – 30 V
sis ground ON Max. 1 V
Circuit diagram related to window washer motor of machine monitor
E-17 Machine push-up function does not operate normally 1
• Machine push-up function does not oper-

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

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

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

Defective machine push-up Machine push-up
1 S05 (female) Resistance
Possible causes switch (Internal short circuit) switch
and standard Low pressure set Max. 1 z
value in normal Between (1) – (2)
High pressure set Min. 1 Mz
state
2
24V circuit) in wiring harness Wiring harness between S05 (male) (2) –
J07 – V06 (female) (2), – D02 (female) (3) Voltage Max. 1 V
and chassis ground
Circuit diagram related to machine push-up solenoid
E-18 Monitoring function fails to display “boom raise” normally 1
Trouble • Boom RAISE operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code: 01900 (Pressure Switch 1)
mation

Defective boom RAISE PPC out troubleshooting.
oil pressure switch (Internal P06 (male) Boom lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom RAISE Max. 1 z
ness
Wiring harness between CP03 (female) (10) Resis-
– P06 (female) (2) tance
and standard
3
(Short circuit with GND cir- Wiring harness between CP03 (female) (10) Resis-
cuit) Min. 1 Mz
– P06 (female) (2) and chassis ground tance
4
Voltage Max. 1 V
5 Defective pump controller CP03 Boom lever Voltage
Between (10) – chas- Neutral 20 – 30 V
sis ground Boom RAISE Max. 1 V
Circuit diagram related to boom RAISE PPC oil pressure switch
E-19 Monitoring function fails to display “boom lower” normally 1
• Boom LOWER operation is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
Related infor-
• Monitoring code: 01900 (Output Switch 1)
mation

Defective boom LOWER out troubleshooting.
PPC oil pressure switch P02 (male) Boom lever Resistance
1
short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Boom LOWER Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Boom lever Voltage
sis ground Boom LOWER Max. 1 V
Circuit diagram related to boom LOWER PPC oil pressure switch
E-20 Monitoring function fails to display “arm IN” normally 1
Trouble • Arm IN operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective arm IN pressure out troubleshooting.
sensor P04 (male) Voltage
1
short circuit) Between (3) – (1) 4.5 – 5.5 V
Between (2) – (1) 0.5 – 4.5 V
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
Between (22) – (10) 4.5 – 5.5 V
Between (19) – (10) 0.5 – 4.5 V
Circuit diagram related to arm IN PPC oil pressure switch
E-21 Monitoring function fails to display “arm OUT” normally 1
Trouble • Arm OUT operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective arm OUT PPC oil
1 pressure switch (Internal dis- P08 (male) Arm lever Resistance
connection or short circuit) Neutral Min. 1 Mz
Between (1) – (2)
Arm OUT Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Arm lever Voltage
sis ground Arm OUT Max. 1 V
Circuit diagram related to arm OUT PPC oil pressure switch
E-22 Monitoring function fails to display “bucket CURL” normally 1
Trouble • Bucket CURL is not displayed normally by machine monitoring function (Special functions)
Related infor-
• Monitoring code:01901 (Output Switch 2)
mation

Defective bucket CURL pres-
1 sure sensor (internal discon- P01 (male) Bucket lever Voltage
nection or short circuit) Between (3) – (1) Neutral 4.5 – 5.5 V
Between (2) – (1) CURL 0.5 – 4.5V
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
a :Prepare with starting switch OFF, then turn starting switch ON
Between (22) – (10) 4.5 – 5.5V
Between (13) – (10) 0.5 – 4.5V
Circuit diagram related to Bucket CURL PPC oil pressure switch
E-23 Monitoring function fails to display “bucket DUMP” normally 1
Trouble • Bucket DUMP operation is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective bucket DUMP PPC out troubleshooting.
oil pressure switch (Internal P05 (male) Bucket lever Resistance
1
disconnection or short cir-
cuit) Neutral Min. 1 Mz
Between (1) – (2)
Bucket DUMP Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
5 Defective pump controller CP03 Bucket lever Voltage
sis ground Bucket DUMP Max. 1 V
Circuit diagram related to bucket DUMP PPC oil pressure switch
E-24 Monitoring function fails to display “swing” normally 1
Trouble • Swing is not displayed normally by machine monitoring function (Special function)
Related infor-
mation

Defective swing left PPC oil
1 pressure switch (Internal dis- P07 (male) Swing lever Resistance
Between (1) – (2)
Left Max. 1 z
Defective swing right PPC oil
2 pressure switch (Internal dis- P03 (male) Swing lever Resistance
Between (1) – (2)
Right Max. 1 z
Disconnection in wiring har- Wiring harnesses between CP03 (female) Resis-
ness Max. 1 z
(29) – P03 (male) (2), – P07 (female) (2) tance
Possible causes 3 (Disconnection in wiring or
tor) chassis ground tance
value in normal
state Wiring harness between P07 (female) (1) – Resis-
Max. 1 z
ness
4 Wiring harnesses between CP03 (female)
(Short circuit with GND cir- Resis-
cuit) (29) – P03 (female) (2), – P07 (female) (2) Min. 1 Mz
tance
and chassis ground
5
24V circuit) in wiring harness Wiring harnesses between CP03 (female)
(29) – P03 (female) (2), – P07 (female) (2) Voltage Max. 1 V
and chassis ground
6 Defective pump controller CP03 Bucket lever Voltage
sis ground Left or Right Max. 1 V
Circuit diagram related to right and left swing PPC oil pressure switches
E-25 Monitoring function fails to display “travel” normally 1
Trouble • Travel is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective travel PPC oil out troubleshooting.
pressure switch P09 (male) Travel lever Resistance
1
Between (1) – (2)
Forward or reverse Max. 1 z
ness
– J01 – P09 (female) (2) tance
Max. 1 z
Possible causes
state 3 Wiring harness of CP03 (female) (39) – J01
cuit) – P09 (female) (2), – M14 (female) (2) and Min. 1 Mz
tance
chassis ground
4
24V circuit) in wiring harness Wiring harness of CP03 (female) (39) – J01
– P09 (female) (2), – M14 (female) (2) and Voltage Max. 1 V
chassis ground
sis ground Forward or reverse Max. 1 V
Circuit diagram related to travel PPC oil pressure switch and travel alarm
E-26 Monitoring function fails to display “travel differential pressure”

normally 1
• Travel differential pressure is not displayed normally by machine monitoring function (Special func-
Trouble
tions)
• Travel differential pressure is turned on as a pressure difference occurred between the right and left
Related infor-
travel PPC circuits (during steering).
mation

Defective travel steering out troubleshooting.
PPC oil pressure switch P10 (male) Travel lever Resistance
1
Between (1) – (2)
Left or right only Max. 1 z
ness
and standard
3
cuit) Min. 1 Mz
4
Voltage Max. 1 V
sis ground Left or right only Max. 1 V
Circuit diagram related to travel steering PPC oil pressure switch
E-27 Monitoring function fails to display “service” normally 1
Trouble • Service is not displayed normally by machine monitoring function (Special functions)
Related infor-
mation

Defective service (front) PPC out troubleshooting.
oil pressure switch S10 (male) Service pedal Resistance
1
Between (1) – (2)
Front Max. 1 z
Defective service (rear) PPC out troubleshooting.
oil pressure switch S11(male) Service pedal Resistance
2
Between (1) – (2)
Rear Max. 1 z
Disconnection in wiring har- Wiring harness between CP02 (female) (35) Resis-
ness Max. 1 z
– S10 (female) (2), – S11 (female) (2) tance
Possible causes 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between S10 (female) (1) – Resis-
tor) chassis ground tance
value in normal
state Wiring harness between S11 (female) (1) – Resis-
Max. 1 z
ness
4 Wiring harness between CP02 (female) (35)
cuit) – S10 (female) (2), – S11 (female) (2) and Min. 1 Mz
tance
chassis ground
5
– S10 (female) (2), – S11 (female) (2) and Voltage Max. 1 V
chassis ground
6 Defective pump controller CP02 Service pedal Voltage
sis ground Front or rear Max. 1 V
Circuit diagram related to service PPC oil pressure switch
E-28 KOMTRAX system does not operate normally 1
Trouble • KOMTRAX system does not operate normally.

• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
Related infor-
carry out following troubleshooting.
mation
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.

a Turn starting switch OFF, then carry out troubleshooting.
LED (1) Normal state
LED-A1 Lighted up
1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshoot-
G01 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37), (38) ply
a Turn starting switch ON and carry out troubleshooting.
2 Defective GPS LED (2) Normal state
LED-A2 Lighted up
a Start engine and carry out troubleshooting.
LED-C1 Lighted up
Defective starting switch
3 ACC signal and alternator R
Possible causes signal G01 Signal Voltage
and standard Between (36) –
value in normal Starting switch ACC 20 – 30 V
(37), (38)
state
Between (28) –
Alternator R 20 – 30 V
(37), (38)
LED-C3 Lighted up
Defective S-NET connection
4 and carry out troubleshooting.
and starting switch C signal
G01 Signal Voltage
Between (10) – (9) S-NET 6–9V
Between (27) –
Starting switch C Max. 1 V
(37), (38)
LED-C4 Lighted up
5 State of CAN connection a Prepare with starting switch OFF and carry out troubleshoot-
ing.
G01 Signal Resistance
Between (7) – (8) CAN 40 – 80 z

Number of mails not trans-
6 LED (12) Normal state
mitted yet
Possible causes 7-segment 0–9
and standard a Turn starting switch ON and carry out troubleshooting (See *)
value in normal
state
7 State of positioning with GPS Dot ON
* In an outdoor location within radio waves' penetration range, it
sometimes takes more than a minute from turning on of the starting
switch to completion of the positioning.
LED display unit G01 connector
E-29 Air conditioner does not operate 1
Trouble • Air conditioner does not start.

Related infor- • For electrical circuit inside the air conditioner unit, refer to the structure, function and maintenance
mation standard, “Air conditioner system.”

1 Defective fuse No. 11 If fuse is burnt, circuit probably has ground fault.
Defective A/C Hi/Lo pressure a Prepare with starting switch OFF, then carry out troubleshoot-
switch ing without turning starting switch ON.
2
(Internal disconnection or P17 (male) Resistance
defective contact) Between (1) – (2) Max. 1 z
Wiring harness between F01-11 outlet – M26 Resis-
(male) (5) tance
ness
Wiring harness between M26 (male) (12) – Resis-
and standard tor) Wiring harness between M26 (male) (8) – Resis-
Max. 1 z
value in normal chassis ground tance
state Wiring harness between P17 (female) (2) – Resis-
Max. 1 z
J04 – A07 – chassis ground tance
ness Wiring harness between F01-11 outlet – M26 Resis-
4 Min. 1 Mz
(Short circuit with GND cir- (male) (5) and chassis ground tance
cuit)
Wiring harness between M26 (male) (12) – Resis-
Min. 1 Mz
5 Defective air conditioner unit (The table indicates internal defect of an air conditioner)
M26 Voltage
Between (5) – (8) 20 – 30 V
Circuit diagram related to air conditioner
E-30 Travel alarm does not sound or does not stop sounding 1
• Alarm does not sound during travel.

Trouble
• Alarm sounds in stopped state.
Related infor-
—
mation

shooting No. E-21.
2 Defective travel signal Operation of lever:

019 Travel ON
When the monitoring display is not correct, proceed to diagnosis for
“'Travel is not normally indicated' in the monitoring function”
out troubleshooting (insert T-adapter).
Defective travel alarm M14 Travel lever Voltage

3 (Internal disconnection or Neutral Max. 1 V
Possible causes Between (1) – (2)
short circuit)
and standard Operated 20 – 30 V
value in normal If above voltage is normal and travel alarm does not sound, travel
state alarm is defective.
ness
Wiring harness between F01-15 outlet – J03 Resis-
– A07 – M14 (female) (1) tance
tor) Wiring harness between M14 (female) (2) – Resis-
Max. 1 z
J01 (19) tance
ness
5 Wiring harness between F01-15 outlet – J03
cuit) – A07 – M14 (female) (1) and chassis Min. 1 Mz
tance
ground
6 Defective pump controller causes 1 – 5 above are not detected, travel alarm may be defec-
tive.)
Circuit diagram related to travel PPC oil pressure switch and travel alarm
E-31 Horn does not sound 1
Trouble Horn does not sound

Related infor-
mation

1 Defective fuse No. 5 If fuse is broken, circuit probably has ground fault. (See Cause 6)
2 Defective horn relay If the horn sounds after replacing the relay, the relay was defective
Between M07 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
3 Defective high tone horn a Prepare with starting switch OFF, then carry out troubleshoot-
Resis-
Between M07 (female) (1) – chassis ground Max. 1 z
tance
If above is normal, the horn is defective
Between M08 (2) – chassis ground (with
Voltage 20 – 30 V
horn switch turned ON)
4 Defective low tone horn a Prepare with starting switch OFF, then carry out troubleshoot-
Possible causes Resis-
Between M08 (female) (1) – chassis ground Max. 1 z
and standard tance
value in normal If above is normal, the horn is defective
state
Wiring harness between F01 (5) – S10 Resis-
(female) – R08 (female) (3) tance
ness
R08 (female) – A07 – M07 (female) (2) tance
tor) Wiring harness between R08 (female) (5) – Resis-
Max. 1 z
A07 – M08 (female) (2) tance
Max. 1 z
J04 (male) (18) – A07 – chassis ground tance
Wiring harness between F01 (5) – S10
Resis-
Ground fault in wiring har- (female) – R08 (female) (3) and chassis Min. 1 Mz
tance
ness ground
6
(Short circuit with GND cir- Wiring harness between S10 (female) (2) –
cuit) Resis-
R08 (female) – A07 – M07 (female) (2) and Min. 1 Mz
tance
chassis ground
Min. 1 Mz
A07 – M08 (female) (2) and chassis ground tance
Circuit diagram related to horn
UEN02651-00

© 2007 KOMATSU
All Rights Reserved
66
UEN02652-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Troubleshooting of hydraulic and mechanical
system (H-mode)
System chart for hydraulic and mechanical system ........................................................................................ 4
Information contained in troubleshooting table ............................................................................................... 6
H-1 All work equipment lack power, or travel and swing speeds are slow...................................................... 8
H-2 Engine speed sharply drops or engine stalls.......................................................................................... 10
H-3 No work equipment, swing or travel move ..............................................................................................11
H-4 Abnormal noise is heard from around hydraulic pump............................................................................11
H-5 Auto-decelerator does not work ............................................................................................................. 12
H-6 Fine control mode does not function or responds slow.......................................................................... 12
H-7 Boom moves slowly or lacks power ....................................................................................................... 13
H-8 Arm moves slowly or lacks power .......................................................................................................... 14
H-9 Bucket moves slowly or lacks power...................................................................................................... 15
H-10 Work equipment does not move in its single operation........................................................................ 15
H-11 Work equipment has a bit too fast hydraulic drift.................................................................................. 16
H-12 Work equipment has big time lag ......................................................................................................... 18
H-13 Other work equipment moves when relieving single circuit.................................................................. 18

H-14 Power max. switch does not operate ................................................................................................... 18
H-15 Machine push-up function does not operate. ....................................................................................... 19
H-16 In compound operation of work equipment, speed of part loaded more is low .................................... 20
H-17 When machine swings and raises boom simultaneously, boom rising speed is low ............................ 20
H-18 When machine swings and travels simultaneously, travel speed lowers largely.................................. 20
H-19 Machine deviates during travel............................................................................................................. 21
H-20 Travel speed is low............................................................................................................................... 22
H-21 Machine is not steered well or steering power is low ........................................................................... 23
H-22 Travel speed does not change or travel speed is low or high .............................................................. 24
H-23 Travel system does not move (only one side) ...................................................................................... 25
H-24 Upper structure does not swing............................................................................................................ 26
H-25 Swing acceleration or swing speed is low ............................................................................................ 28
H-26 Upper structure overruns remarkably when it stops swinging .............................................................. 30
H-27 Large shock is made when upper structure stops swinging ................................................................. 31
H-28 Large sound is made when upper structure stops swinging. ............................................................... 31
H-29 Hydraulic drift of swing is large............................................................................................................. 32
H-30 Attachment circuit is not changed ........................................................................................................ 33
H-31 Oil flow in attachment circuit cannot be controlled ............................................................................... 33
System chart for hydraulic and mechanical system 1
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as
a reference material when troubleshooting the hydraulic and mechanical system.
Information contained in troubleshooting table 1

a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure
Phenomenon occurring on machine
phenomenon
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting
Presumed 2
Cause for presumed failure
cause and [Contents]
(The attached No. is for fil-
standard value • The standard values in normalcy by which to judge “Good”
3 ing and reference purpose
in normalcy or “No Good” about presumed causes.
only. It does not stand for
• References for making judgement of “good” or “No Good”
any priority.)
4
H-1 All work equipment lack power, or travel and swing speeds are slow1
Trouble • Speed or power of all work equipment, travel, and swing is low
Related
• Set the working mode in P-mode before start.
information

a Prepare with engine stopped, then run engine at high
idle and carry out troubleshooting.
1 Malfunction of unload valve Control lever Unload pressure
4.12 ± 1.0 MPa
All levers in neutral
{42 ± 10 kg/cm2}
Control lever Main relief pressure
Defective adjustment or mal- 33.34 – 36.77 MPa
2 Arm IN
function of main relief valve {340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
Malfunction of self pressure
Possible causes 3 Control lever Control circuit basic pressure
reducing valve
and standard 2.84 – 3.43 MPa
value in normal All levers in neutral
{29 – 35 kg/cm2}
state
Measured oil Measurement condi-
Oil pressure ratio
pressure tion
Defective adjustment or mal- Pump discharge
4 1
function of PC valve pressure Swing lock switch: ON
PC valve output Arm IN relief Approx. 0.6
If oil pressure does not become normal after adjustment, PC valve
may have malfunction or internal defect. Check PC valve directly.
LS-EPC output
Travel speed Travel lever
5 Malfunction of LS-EPC valve pressure
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Hi Lifting operation 0 MPa {0 kg/cm2}

Oil pressure ratio
Measured oil Travel with no load
pressure All levers in neutral (Lever operated
Possible causes Defective adjustment or mal- halfway)
6
and standard function of LS valve Pump discharge
value in normal 1
pressure Almost same pres-
state sure
LS valve output Approx. 0.6
If oil pressure does not become normal after adjustment, LS valve
may have malfunction or internal defect. Check LS valve directly.
7 Malfunction of servo piston Servo piston may have malfunction. Check it directly.
If any cause above is detected, cause may be lowering of perfor-
8 Defective piston pump
mance, malfunction, or internal defect of piston pump.
H-2 Engine speed sharply drops or engine stalls 1

Trouble • Engine speed lowers extremely or engine stalls.
Related
information

Control lever Main relief pressure
Defective adjustment or mal- 33.34 – 36.77 MPa
1 Arm IN
function of main relief valve {340 – 375 kg/cm2}
If oil pressure does not become normal after adjustment, main relief
valve may have malfunction or internal defect. Check main relief
valve directly.
Measured oil Measurement
Oil pressure ratio
pressure condition
Defective adjustment or mal- Pump discharge
2 1
function of PC valve pressure Swing lock switch: ON
Possible causes PC valve output Arm IN relief Approx. 0.6
and standard pressure (Approx. 3/5)
value in normal If oil pressure does not become normal after adjustment, PC valve
state may have malfunction or internal defect. Check PC valve directly.
Oil pressure ratio
Defective adjustment or mal- halfway)
3
function of LS valve Pump discharge
1
pressure Almost same
LS valve output pressure Approx. 0.6
Clogging of orifice or filter in Orifices or filters in pump servo devices may be clogged. Check
4
servo devices them directly.
H-3 No work equipment, swing or travel move 1

Trouble • All work equipment, swing, and travel mechanism do not move.
Related
information

Malfunction of PPC lock Safety lock lever Solenoid output pressure
1
solenoid valve Lock 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Free
{29 – 35 kg/cm2}
Possible causes a Prepare with engine stopped, then run engine at high
and standard idle and carry out troubleshooting.
value in normal Malfunction of self pressure
state 2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
• Piston pump may have malfunction or internal defect. Check it by
following method.
3 Defective piston pump
Crank the engine with oil pressure measurement plug removed.
If oil flows out, the piston pump is normal.
Pump shaft may not revolve because of defect in damper. Check
4 Defective damper
damper directly.
H-4 Abnormal noise is heard from around hydraulic pump 1

Failure
• An abnormal noise is heard from around hydraulic pump.
phenomenon
Relative
information
Cause Standard value in normalcy and references for troubleshooting

1 Hydraulic oil level lowered Make a visual check.
2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.
Presumed It is presumed that the cap of hydraulic tank is clogged, thereby
cause and 3 Hydraulic tank cap clogged
causing negative pressure inside the tank. Make a visual check.
standard value
It is presumed that the strainer in the hydraulic tank is clogged,
in normalcy Hydraulic tank strainer
4 thereby causing negative pressure in the suction circuit. Make a
clogged
visual check.
The piston pump is suspected of an internal failure. Check the pump
5 Piston pump defective
itself.
H-5 Auto-decelerator does not work 1

Trouble • Auto-decelerator does not operate.
• Carry out this troubleshooting if auto-decelerator does not operate when travel lever is operated.
Related (Shuttle valve (in PPC valve) is installed between PPC valve and oil pressure switch of only in travel
information circuit.)

Possible causes idle and carry out troubleshooting.
and standard
Malfunction of travel PPC Travel lever PPC valve output pressure
value in normal 1
state valve (shuttle valve) Neutral 0 MPa {0 kg/cm2}
Min. 2.75 MPa
Operated
{Min. 28 kg/cm2}
H-6 Fine control mode does not function or responds slow 1

Trouble • Fine control performance or response is low.
Related
information

LS-EPC output
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
2 Clogging of LS circuit orifice Orifice of LS circuit may be clogged. Check it directly.
Possible causes a Prepare with engine stopped, then run engine at high
and standard idle and carry out troubleshooting.
value in normal
state Oil pressure ratio
Defective adjustment or mal- halfway)
3
function of LS valve Pump discharge
1
pressure Almost same pres-
LS valve output sure Approx. 0.6
H-7 Boom moves slowly or lacks power 1

Trouble • Speed or power of boom is low
Related
information

R.H. work equipment control
Malfunction of right PPC PPC valve output pressure
1 lever
valve (boom circuit)
Neutral 0 MPa {0 kg/cm2}
In boom Raise operation Min. 2.75 MPa
In boom Lower operation {Min. 28 kg/cm2}
Malfunction of merge-divider Travel lever Solenoid output pressure
2
solenoid valve At neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
Malfunction of merge-divider Merge-divider valve (main/LS) of control valve may have malfunc-
3
valve (main/LS) tion. Check it directly.
Malfunction of boom control Spool of boom control valve (Lo/Hi) may have malfunction. Check it
4
valve (spool) directly.
Malfunction of boom control
Possible causes Pressure compensation valve of boom control valve (Lo/Hi) may
5 valve (pressure compensa-
and standard have malfunction. Check it directly.
tion valve)
value in normal
state Malfunction of boom control Regeneration valve of boom control valve (Lo) may have malfunc-
6
valve (regeneration valve) tion or defective seal. Check it directly.
Malfunction of boom control Lock valve of boom control valve (Lo) may have malfunction. Check
7
valve (lock valve) it directly.
Malfunction of boom control Check valve of boom control valve (Hi) may have malfunction.
8
valve (check valve) Check it directly.
Malfunction or defective seal Safety valve for lock valve may have malfunction or defective seal.
9
of safety valve for lock valve Check it directly.
Malfunction or defective seal
Suction valve (bottom side) of boom control valve (Lo) may have
10 of boom control valve
malfunction or defective seal. Check it directly.
(suction valve)
Safety-suction valve (head side) of boom control valve (Lo) may
11 of boom control valve
have malfunction or defective seal. Check it directly.
(safety-suction valve)
Malfunction of LS shuttle
LS shuttle valve of left travel control valve, bucket control valve, or
12 valve
service control valve may have malfunction. Check it directly.
(left travel, bucket, or service)
13 Defective boom cylinder
Boom cylinder Leakage from cylinder
Boom raise relief 20 cc/min
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
H-8 Arm moves slowly or lacks power 1

Trouble • Speed or power of arm is low
Related
information

L.H. work equipment control
Malfunction of left PPC valve PPC valve output pressure
1 lever
(arm circuit)
At neutral 0 MPa {0 kg/cm2}
During arm IN operation Min. 2.75 MPa
During arm OUT operation {Min. 28 kg/cm2}
2
2.84 – 3.43 MPa
Operated (Note)
{29 – 35 kg/cm2}
Malfunction of pump merge- Pump merge-divider valve (main/LS) of control valve may have mal-
3
Possible causes divider valve (main/LS) function. Check it directly.
and standard Malfunction of arm control Spool of arm control valve (Lo/Hi) may have malfunction. Check it
value in normal 4
state
Malfunction of arm control
Pressure compensation valve of arm control valve (Lo/Hi) may have
malfunction. Check it directly.
tion valve)
Malfunction of arm control Regeneration valve of arm control valve (Lo) may have malfunction
6
valve (regeneration valve) or defective seal. Check it directly.
Safety-suction valve of arm control valve (Lo/Hi) may have malfunc-
7 of arm control valve (safety-
tion or defective seal. Check it directly.
suction valve)
Malfunction of arm control Quick return valve of arm control valve (Hi) may have malfunction.
8
valve (quick return valve) Check it directly.
Malfunction of LS shuttle LS shuttle valve of right travel control valve, boom control valve, left
9 valve (right travel, boom, left travel control valve, bucket control valve, or service control valve
travel, bucket, or service) may have malfunction. Check it directly.
10 Defective arm cylinder
Arm cylinder Leakage from cylinder
Arm IN relief 20 cc/min
Note: Fine operation just enough to turn on PPC oil pressure switch is acceptable for travel lever.
H-9 Bucket moves slowly or lacks power 1

Trouble • Speed or power of bucket is low
Related
information

R.H. work equipment control
Malfunction of right PPC PPC valve output pressure
1 lever
valve (bucket circuit)
During bucket CURL operation Min. 2.7 MPa
During bucket DUMP operation {Min. 28 kg/cm2}
Malfunction of bucket control Spool of bucket control valve may have malfunction. Check it
2
Possible causes valve (spool) directly.
and standard Malfunction of bucket control
value in normal Pressure compensation valve of bucket control valve may have mal-
state function. Check it directly.
tion valve)
Safety-suction valve of bucket control valve may have malfunction
4 of bucket control valve
or defective seal. Check it directly.
Malfunction of LS shuttle LS shuttle valve of service control valve may have malfunction.
5
valve (service) Check it directly.
6 Defective bucket cylinder
Bucket cylinder Leakage from cylinder
CURL relief 20 cc/min
H-10 Work equipment does not move in its single operation 1

(1) Boom does not move singly.
Trouble • Work equipment does not move singly (2) Arm does not move singly..
(3) Bucket does not move singly.
Related
information

Possible causes Work equipment control lever PPC valve output pressure
and standard 1 Malfunction of PPC valve
value in normal At neutral 0 MPa {0 kg/cm2}
state Min. 2.75 MPa
Operated
{Min. 28 kg/cm2}
Malfunction of control valve
2 Spool of control valve may have malfunction. Check it directly.
(spool)
H-11 Work equipment has a bit too fast hydraulic drift 1

Trouble • Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large.
Related
information

Possible causes 1 Defective boom cylinder
Boom cylinder Leakage from cylinder
and standard
value in normal Boom RAISE relief 20 cc/min
state Defect in seal of boom con- Seal of lock valve of boom control valve (Lo) may be defective.
2
trol valve (lock valve) Check it directly.
Defective seal of safety valve
3 Seal of safety valve for lock valve may be defective. Check it directly.
for lock valve
Trouble • Hydraulic drift of work equipment is large (2) Hydraulic drift of arm is large.
Related
information

1 Defective arm cylinder
Arm cylinder Leakage from cylinder
Arm IN relief 20 cc/min
Possible causes Seal of safety-suction valve of arm control valve (Lo/Hi) may be
and standard defective. Check it directly.
Defective seal of arm control
value in normal 2 (When troubleshooting this safety-suction valve, it is allowed to
valve (safety-suction valve)
state replace it with another one to see the change in phenomena and
judge its acceptability.)
Defective seal of arm control Seal of spool of arm control valve (Lo/Hi) may be defective. Check it
3
Defective seal of arm control
Seal of pressure compensation valve (bottom side) of arm control
valve (Lo/Hi) may be defective. Check it directly.
tion valve)
Trouble • Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large.
Related
information

1 Defective bucket cylinder
Bucket cylinder Leakage from cylinder
Bucket curl relief 20 cc/min
Possible causes Seal of safety-suction valve of bucket control valve may defective.
and standard Defective seal of bucket con- Check it directly.
value in normal 2 trol valve (safety-suction (When troubleshooting this safety-suction valve, it is allowed to
state valve) replace it with another one to see the change in phenomena and
Defective seal of bucket con- Seal of bucket control valve spool may be defective. Check it
3
trol valve (spool) directly.
Defective seal of valve con-
Seal of pressure compensation valve (bottom side) of bucket control
4 trol valve (pressure compen-
valve may be defective. Check it directly.
sation valve)
H-12 Work equipment has big time lag 1

Trouble • Time lag of work equipment is large.
Related
information

LS-EPC output
Approx. 1.37 MPa
Lo Neutral
{Approx. 14 kg/cm2}
Possible causes Hi Lifting operation 0 MPa {0 kg/cm2}
and standard
value in normal Malfunction of control valve
Regeneration valve of control valve may have malfunction. Check it
state 2 (regeneration valve)
directly.
[boom and arm only]
Safety-suction valve (Boom: Head side, Arm/Bucket: Bottom side)
of control valve may have malfunction. Check it directly.
Malfunction of control valve
3 (When troubleshooting this safety-suction valve, it is allowed to
replace it with another one to see the change in phenomena and
Malfunction of control valve Pressure compensation valve of control valve may have malfunc-
4
(pressure compensation valve) tion. Check it directly.
H-13 Other work equipment moves when relieving single circuit 1

Trouble • When part of work equipment is relieved singly, other parts of work equipment move
Related
information

and standard Defective seal of control
value in normal Seal of pressure compensation valve of control valve may be defec-
state tive. Check it directly.
tion valve)
H-14 Power max. switch does not operate 1

Trouble • The power maximizing function does not work.
Related
information

Possible causes
and standard Malfunction of 2-stage relief Swing lock switch Solenoid output pressure
1
value in normal solenoid valve OFF 0 MPa {0 kg/cm2}
state
2.84 – 3.43 MPa
ON
{29 – 35 kg/cm2}
2 Malfunction of main relief valve Main relief valve of control valve may have malfunction. Check it directly.
H-15 Machine push-up function does not operate. 1

Trouble • Machine push-up function does not operate.
Related
information

Possible causes Machine push-up switch Solenoid output pressure
Malfunction of machine
and standard 1
push-up solenoid valve Min. 2.75 MPa
value in normal OFF
state {Min. 28 kg/cm2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom control Malfunctioning of safety-suction valve (high-voltage set side of head
2
valve (safety-suction valve) side) of boom control valve (Lo) is suspected. Check it directly.
H-16 In compound operation of work equipment, speed of part loaded

more is low 1
Trouble • In compound operation of work equipment, speed of part loaded more is low.
Related
—
information

Malfunctioning of pressure compensation valve on smaller load side
is suspected. Check it directly.
Combinations in com-
Larger load side Smaller load side
pound operation
Boom RAISE +
Possible causes Boom Arm
Arm IN
and standard
value in normal Malfunction of control valve Boom RAISE +
1 Arm Boom
state on smaller load side Arm OUT
Boom RAISE +
Boom Bucket
Bucket CURL
Arm OUT +
Arm Bucket
Bucket CURL
Boom LOWER +
Arm Boom
Arm OUT
H-17 When machine swings and raises boom simultaneously, boom

rising speed is low 1
Trouble • When machine swings and raises boom simultaneously, boom rising speed is low.
Related
• If speed of single boom raise operation is also low, carry out troubleshooting H-7 first.
information

and standard
value in normal Malfunction or defective seal LS select valve of control valve may have malfunction or defective
1
state of LS selector valve seal. Check them directly.
H-18 When machine swings and travels simultaneously, travel speed

lowers largely 1
Trouble • When machine swings and travels simultaneously, travel speed lowers largely.
Related
• If speed of single travel operation is also slow, carry out troubleshooting of H-20 first.
information

and standard
value in normal Malfunction of LS shuttle LS shuttle valve of left travel control valve or swing control valve
1
state valve (left travel and swing) may have malfunction. Check it directly.
H-19 Machine deviates during travel 1

Trouble • Machine deviates during travel.
Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.75 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left Within 0.4 MPa
outputs {Within. 4 kg/cm2}
2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
Oil pressure ratio
Defective adjustment or mal- pressure All levers in neutral (Lever operated
3
Possible causes function of LS valve halfway)
and standard Pump discharge
value in normal 1
pressure Almost same
state pressure
LS valve output Approx. 0.6
Malfunction of travel junction Travel lever Solenoid output pressure
4
solenoid valve Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
When either side operated
{29 – 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
5
valve Check it directly.
Malfunction of travel control
6 Spool of travel control valve may have malfunction. Check it directly.
valve (spool)
7 Defective travel motor
Travel lever Leakage from travel motor
Travel relief Max. 40 l/min
Final drive may have internal defect. Check it directly.
8 Defective final drive (It may be checked by abnormal sound, abnormal heating, metal
chips in drain oil, etc.)
H-20 Travel speed is low 1

Trouble • Travel speed is low.
Related
information

Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.75 MPa
valve Travel forward or reverse
{Min. 28 kg/cm2}
Difference between right and left/ Within 0.4 MPa
forward and reverse outputs {Within. 4 kg/cm2}
2 Control lever Control circuit basic pressure
reducing valve
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
LS-EPC output
Possible causes 3 Malfunction of LS-EPC valve pressure
and standard
Approx. 1.37 MPa
value in normal Lo Neutral
{Approx. 14 kg/cm2}
state
valve (spool)
Pressure compensation valve of travel control valve may have mal-
function. Check it directly.
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
6
valve (suction valve) directly.
Malfunction of LS shuttle LS shuttle valve of bucket control valve may have malfunction.
7
valve (bucket) Check it directly.
8 Defective travel motor
Travel lever Leakage from travel motor
H-21 Machine is not steered well or steering power is low 1

Trouble • Machine is not steered well or steering power is low
Related
information

PPC valve output pressure
Malfunction of travel PPC Travel lever
1 (Steering)
valve (steering spool)
Both sides in neutral 0 MPa {0 kg/cm2}
Min. 2.75 MPa
When either side operated
{Min. 28 kg/cm2}
Malfunction of travel junction Travel lever Solenoid output pressure
2
2.84 – 3.43 MPa
Either side operated
{29 – 35 kg/cm2}
Malfunction of travel junction Travel junction valve of travel control valve may have malfunction.
3
valve Check it directly.
4
Possible causes
and standard 2.84 – 3.43 MPa
Operated
value in normal {29 – 35 kg/cm2}
state Malfunction of merge-divider Merge-divider valve of control valve may have malfunction. Check it
5
valve directly.
valve (spool)
Pressure compensation valve of travel control valve may have mal-
tion valve)
Malfunction of travel control Suction valve of travel control valve may have malfunction. Check it
8
valve (suction valve) directly.
Malfunction of LS shuttle LS shuttle valve of bucket control valve may have malfunction.
9
valve (bucket) Check it directly.
Defect in seal of check valve Seal of check valve of LS pressure sensing part may be defective.
10
of LS pressure sensing part Check it directly.
Seal of safety valve of travel motor may have malfunction. Check it
directly.
Malfunction of travel motor
11 (Motors of same type on forward and reverse sides or on right and
(safety valve)
left sides may be checked by replacing them with each other and
seeing change of condition.)
Check valve of travel motor may have defective seal. Check it
directly.
Malfunction of travel motor
12 (Motors of same type on forward and reverse sides or on right and
(check valve)
left sides may be checked by replacing them with each other and
seeing change of condition.)
H-22 Travel speed does not change or travel speed is low or high 1
Trouble • Travel speed does not change or travel speed is or low or high
Related
information

Monitoring
[01500]
Lo Fine control 690 mA
Mi (such as releasing 740 mA
Hi decelerator) 0 mA
1 Malfunction of LS-EPC valve
Possible causes LS-EPC output pres-
and standard sure
value in normal Approx. 1.37 MPa
state Lo Neutral
{Approx. 14 kg/cm2}
Solenoid valve out-
Malfunction of travel speed Travel speed Travel lever
2 put pressure
selector solenoid valve
Lo Neutral 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Hi Operated
{29 – 35 kg/cm2}
Malfunction of travel motor Speed shifting section of travel motor may have malfunction. Check
3
(speed shifting section) it directly.
H-23 Travel system does not move (only one side) 1

Trouble • Travel system does not move (only one side).
Related
information

Defective seal of travel con- Suction valve of travel control valve may have defective seal. Check
1
trol valve (suction valve) it directly.
Defective seal of travel motor Safety valve of travel motor may have defective seal. Check it
2
(safety valve) directly.
Possible causes Defective seal of travel motor Check valve of travel motor may have defective seal. Check it
3
and standard (check valve) directly.
value in normal a Prepare with engine stopped, then run engine at high
state idle and carry out troubleshooting.
Lowering of travel motor out-
4
put Travel lever Leakage from travel motor
H-24 Upper structure does not swing 1

Trouble • Upper structure does not swing. (1) Upper structure does not swing in either direction.
Related
information

R.H. work equipment
Malfunction of swing holding Solenoid valve output pressure
1 control lever
brake solenoid valve
2.84 – 3.43 MPa
In swing operation
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check
2
(holding brake) it directly.
Possible causes
and standard L.H. work equipment
Swing lock switch Swing relief pressure
value in normal Defective adjustment or mal- control lever
state 3 function of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
{285 – 335 kg/cm2}
If oil pressure does not become normal after adjustment, safety
valve may have malfunction or internal defect. Check safety valve
directly.
4 Defective swing motor L.H. work equipment
Leakage from swing motor
control lever
Swing relief Max. 11 l/min
Swing machinery may have internal defect. Check it directly.
5 Defective swing machinery (It may be checked by abnormal sound, abnormal heating, metal
Trouble • Upper structure does not swing. (2) Upper structure swings only in one direction.
Related
information

Malfunction of swing PPC PPC valve output pressure
1 lever
valve
Min. 2.75 MPa
Possible causes In swing operation
{Min. 28 kg/cm2}
and standard
value in normal Malfunction of swing control
2 Spool of swing control valve may have malfunction. Check it directly.
state valve (spool)
Seal of suction valve of swing motor may be defective. Check it
Defective seal of swing directly.
3
motor (suction valve) (Suction valves on right side and left side may be checked by
replacing them with each other and seeing change of condition.)
Seal of check valve of swing motor may be defective. Check it
4
motor (check valve) (Check valves on right side and left side may be checked by replac-
ing them with each other and seeing change of condition.)
H-25 Swing acceleration or swing speed is low 1

(1) Swing acceleration or swing speed is low in both
Trouble • Swing acceleration or swing speed is low
directions.
Related
information

Malfunction of LS shuttle LS shuttle valves of all control valves may have malfunction. Check
1
valve (all control valves) them directly.
Malfunction of swing motor Holding brake section of swing motor may have malfunction. Check
2
(holding brake) it directly.
L.H. work equipment
Defective adjustment or mal- control lever
Possible causes 3 function of swing motor 27.95 – 32.85 MPa
(safety valve) ON Swing relief
and standard {285 – 335 kg/cm2}
value in normal If oil pressure does not become normal after adjustment, safety
state valve may have malfunction or internal defect. Check safety valve
directly.
4 Defective swing motor L.H. work equipment control
lever
Swing relief a Max. 11 l/min
(2) Swing acceleration or swing speed is low in only one

Trouble • Swing acceleration or swing speed is low
direction.
Related
information

1 lever
valve
Min. 2.75 MPa
In swing operation
{Min. 28 kg/cm2}
Possible causes Malfunction of swing control
2 Spool of swing control valve may have malfunction. Check it directly.
and standard valve (spool)
value in normal
Malfunction of swing control
state Pressure compensation valve of swing control valve may have mal-
tion valve)
4
motor (suction valve) (Suction valves on right side and left side may be checked by
5
motor (check valve) (Check valves on right side and left side may be checked by replac-
H-26 Upper structure overruns remarkably when it stops swinging 1

• Upper structure overruns remarkably when (1) Upper structure overruns remarkably when it stops
Trouble
it stops swinging. swinging in both directions.
Related
information

L.H. work equipment
Defective adjustment or mal- control lever
1 function of swing motor 27.95 – 32.85 MPa
Possible causes (safety valve) ON Swing relief
{285 – 335 kg/cm2}
and standard
value in normal If oil pressure does not become normal after adjustment, safety
state valve may have malfunction or internal defect. Check safety valve
directly.
2 Defective swing motor L.H. work equipment
control lever
Swing relief a Max. 11 l/min
• Upper structure overruns remarkably when (2) Swing acceleration or swing speed is low in only one
Trouble
it stops swinging. direction.
Related
information

1 lever
valve
Min. 2.75 MPa
In swing operation
{Min. 28 kg/cm2}
Possible causes Swing PPC slow return valve may be clogged. Check it directly.
Clogging of swing PPC slow
and standard 2 (Slow return valves on right side and left side may be checked by
return valve
value in normal replacing them with each other and seeing change of condition.)
state
3 Swing control valve spool may be malfunctioning. Check it directly.
valve (spool)
4
motor (suction valve section) (Suction valves on right side and left side may be checked by
5
motor (check valve section) (Check valves on right side and left side may be checked by replac-
H-27 Large shock is made when upper structure stops swinging 1

Trouble • Large shock is made when upper structure stops swinging.
Related
information

L.H. work equipment
1 control lever
valve
Possible causes At neutral 0 MPa {0 kg/cm2}
and standard
Min. 2.75 MPa
value in normal In swing operation
{Min. 28 kg/cm2}
state
Swing PPC slow return valve may have malfunction. Check it
Malfunction of swing PPC directly.
2
slow return valve (Slow return valves on right side and left side may be checked by
Malfunction of swing motor Shockless valve of swing motor may have malfunction. Check it
3
(shockless valve) directly.
H-28 Large sound is made when upper structure stops swinging. 1

Trouble • Large sound is made when upper structure stops swinging.
Related
information

Malfunction of back pres- Back pressure valve of control valve may have malfunction. Check it
1
sure valve directly.
Malfunction of swing motor
2 Safety valve of swing motor may have malfunction. Check it directly.
Possible causes (safety valve)
and standard Seal of suction valve of swing motor may be defective. Check it
value in normal Malfunction of swing motor directly.
state 3
(suction valve) (Suction valves on right side and left side may be checked by
H-29 Hydraulic drift of swing is large 1

Trouble • Hydraulic drift of swing is large. (1) When swing holding brake is in operation
• When swing lock switch is turned ON or when swing holding brake release switch is in normal posi-
Related
tion, swing holding brake is activated, fixing upper structure with disc brake.
information

Possible causes R.H. work equipment
Malfunction of swing holding Solenoid valve output pressure
and standard 1 control lever
brake solenoid valve
value in normal At neutral 0 MPa {0 kg/cm2}
state
2.84 – 3.43 MPa
In swing operation
{29 – 35 kg/cm2}
Malfunction of swing motor Holding brake section of swing motor may have malfunction or inter-
2
(holding brake) nal defect. Check it directly.
Trouble • Hydraulic drift of swing is large. (2) When swing holding brake is released
• When swing holding brake release switch is in emergency position, swing holding brake is released
Related
and upper structure is secured only by oil pressure.
information

Malfunction of swing control Seal of spool of swing control valve may be defective. Check it
1
Seal of pressure compensation valve section of swing control valve
may be defective. Check it directly.
tion valve)
Possible causes
Defective seal of swing
and standard 3 Seal of safety valve of swing motor may be defective. Check it directly.
motor (safety valve)
value in normal
state Defective seal of swing
4 Seal of suction valve of swing motor may be defective. Check it directly.
motor (suction valve)
Defective seal of swing
5 Seal of check valve of swing motor may be defective. Check it directly.
motor (check valve)
Malfunction of defective seal
Shockless valve of swing motor may have malfunction or defective
6 of swing motor (shockless
seal. Check it directly.
valve)
H-30 Attachment circuit is not changed 1

Trouble • Attachment circuit is not changed.
• On a machine equipped with attachment, service circuit is changed as follows according to selected
working mode.
1) When P- or E-mode is selected: Double acting circuit is selected, setting safety valve to low-pres-
Related sure set.
information 2) When B-mode is selected: Single acting circuit is selected, setting safety valve to high-pressure
setting.
* B port alone allows changing the set of safety valve. The valve remains constantly at low-pressure
set on A port side.

a Prepare with engine stopped, then run engine at high idle and
carry out troubleshooting.
Malfunction of service return Working mode Solenoid valve output pressure
Possible causes 1
solenoid valve P- or E-mode 0 MPa {0 kg/cm2}
and standard
value in normal 2.84 – 3.43 MPa
B-mode
state {29 – 35 kg/cm2}
Malfunction of service return Service return selector valve may have malfunction. Check it
2
valve directly.
Malfunction of service control Safety valve (B port side) of service control valve may have mal-
3
valve (safety valve) function. Check it directly.
H-31 Oil flow in attachment circuit cannot be controlled 1

Trouble • Oil flow in attachment circuit cannot be controlled.
• On a machine equipped with attachment, flow rate in service circuit changes depending on the mode
Related chosen from select mode.
information • Procedure for adjusting flow rate is not identical between P- or E-mode and B-mode. For more infor-
mation, see Operation and Maintenance Manual.

Malfunction of service
1 Service current EPC valve may have malfunction. Check it directly.
current EPC valve
Possible causes a Prepare with engine stopped, then run engine at high idle and
and standard carry out troubleshooting.
value in normal PPC valve output
Malfunction of service PPC Harness connector Service pedal
state 2 pressure
valve
Disconnect V30 con- At neutral 0 MPa {0 kg/cm2}
nector of service cur- 2.75 MPa
rent EPC valve. Operated
{28 kg/cm2}
UEN02652-00

© 2007 KOMATSU
All Rights Reserved
34
UEN02653-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operations .............................................................................................................. 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 17
S-9 Oil becomes contaminated quickly ......................................................................................................... 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 22
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 24
S-15 Abnormal noise is made....................................................................................................................... 25
S-16 Vibration is excessive ........................................................................................................................... 26
Method of using troubleshooting chart 1

The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They
correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can
be drawn from the user or operator, depending on
their level.
Check items:
Simple check items used by the serviceman to nar-
row the causes. They correspond to C in the chart
on the right.
Causes:
Items to be narrowed from the questions and check
items.
The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying
the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or
direct inspection.
Items listed in the [Questions] and [Check items]
and related to the [Causes] are marked with E, Q,
and w.
E : Causes to be referred to for questions and

check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked
with
a When narrowing the “causes”, apply the items
marked with w before those marked with Q.
When narrowing the “causes”, do not apply the
items marked with E (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
<Example of troubleshooting> Exhaust smoke is black
Let us assume that when “Color of exhaust gas is black” occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in “Step 1” to “Step 3” in the figure below to narrow
the [causes] to lead to [troubleshooting].
S-1 Starting performance is poor 1

General causes why starting performance is poor Cause
Cracked EGR cooler (Coolant in exhaust piping)

• Defective electrical system
• Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

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

• Insufficient intake of air
Defective alternator (regulator section)

• Improper selection of fuel
Stuck, seized supply pump plunger
Defective intake air heater system
Defective or deteriorated battery

• Coolant in exhaust piping
Clogged feed pump gauze filter

Clogged air cleaner element
Clogged fuel filter/strainer

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

Degree of use of
Operated for long period E E E E E
machine
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally w
(if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
While engine is cranked not flow out w w
with starting motor
Check items
If spill hose from injector is disconnected, little fuel spills w

When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows out
q
(*1)
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect gauze filter of feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for failure
q
code.
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.
*2: Failure codes [CA559] and [CA2249]
S-2 Engine does not start 1

a) Engine does not turn Cause
Cracked EGR cooler (Coolant in exhaust piping)

General causes why engine does not turn
Defective starting motor (safety relay section)

• Internal parts of engine seized:
Defective connection of battery terminal
Defective starting motor (motor section)

See “S-4 Engine stops during operations”
• Coolant entered in cylinder, producing water hammer
Defective or deteriorated battery

• Defective electrical system
Defective starting circuit wiring

• Defective hydraulic pump
Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Defective battery relay
Degree of use of
Questions
Operated for long period EEE

machine
Condition of horn Horn does not sound Q Q w
when starting switch
is turned ON Horn volume is low w
Battery electrolyte is low w

Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch
is turned to START, Makes grating noise w w
starting pinion moves Soon disengages again w
out, but
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
q
out (*1)
Carry out troubleshooting in H-mode
Carry out troubleshooting in E-mode
Inspect flywheel ring gear directly q

When specific gravity of electrolyte and voltage of battery are measured, they are
q
Troubleshooting
low
There is not voltage (20 – 30 V) between battery relay termi-
q
nal M and terminal E
Turn starting switch When terminal B and terminal C of starting switch are con-
q
OFF, connect cord, nected, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are con-
shooting at ON q
nected, engine starts
Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
—

b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out
• Fuel is not being supplied

• Supply of fuel is extremely small

• Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump

Broken supply pump shaft key
Defective supply pump PCV
Malfunction of flow damper

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use
Questions
Operated for long period EEE

of machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
and Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel does
While engine is not flow out Q Q w Q
cranked with
starting motor If spill hose from injector is disconnected, little fuel
Q w w w w Q
spills

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)”
q q q q
See *1 for failure code.
Carry out troubleshooting for “PCV1 Error (*2) or PCV2 Error (*3).”
q
See *2 or *3 for failure code.
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

c) Exhaust smoke comes but engine does not start Cause
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start
Excessive wear of piston ring, cylinder liner
Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray

Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel
Degree of use of
Operated for long period E EE E
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
w w w
nance Manual
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w w
cranked with starting out
motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for failure code. q
When injector is tested alone, condition of spray is poor q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if the gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
S-3 Engine does not pick up smoothly 1

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

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

• Controller is controlling in derate mode

• (limiting injection rate (output) because of an error in electrical system)

• EGR valve is stuck and is open
(Excessive EGR gas, insufficient intake of air)
Clogged injector, defective spray


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

Non-specified fuel is being used w w w w
w w w
nance Manual
Q w
Color of exhaust Blue under light load w
Check items
gas Black w Q w w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Carry out troubleshooting for “EGR Valve Servo Error. (*1)” See *1 for failure code. q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

S-4 Engine stops during operations 1

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

• Seized parts inside engine
• There is overheating
• Defective hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Broken supply pump shaft key

Leaking, clogged fuel piping
Broken, seized feed pump

Defective hydraulic pump

Broken, seized gear train
Degree of use of
Operated for long period EE
machine
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w
Questions
Condition when engine Engine overheated and stopped w Q

stopped Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
Check items
Metal particles are found when oil pan is drained w w Q Q

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q
Inspect crank shaft bearing directly q

Troubleshooting
Inspect gear train directly q
Inspect feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for code. q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
*1: Code [559/CA559] and code [2249/CA2249] in E-mode
S-5 Engine does not rotate smoothly 1

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

• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicated)
• Defective EGR valve
• Defective bypass valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Low idle speed is set too low
Malfunction of bypass valve

Malfunction of EGR valve

Degree of use of
Operated for long period EE EE
machine
Questions
Occurs at a certain speed range Q Q Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and
w w
Maintenance Manual
Check items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting for “Bypass Valve Servo Error. (*2)” See *2 for failure code. q
Troubleshooting

q q
does not change
Carry out troubleshooting for “Eng Ne Speed Sensor Error. (*3)” See *3 for
q
failure code.
Carry out troubleshooting for “Eng Bkup Speed Sensor Error. (*4)” See *4 for failure
q
code.
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add

*2: Failure codes [CA1628] and [[CA1629]
*3: Failure code [CA689]
*4: Failure code CA778]
S-6 Engine lacks output (or lacks power) 1

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

Defective charge air pressure sensor, wiring harness

Defective fuel temperature sensor, wiring harness

• Defective condition of fuel spray
Clogged injector, defective spray (dirt in injector)

Defective drive of injector (signal, solenoid)

• There is overheating:

See “S-14 Coolant temperature becomes too high (Overheating)”

Air leakage from air intake piping
(limiting injection rate (output) because of an error in electrical system)

Leaking, clogged fuel piping

Degree of use of
machine Operated for long period E E E E E
Questions
Suddenly Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q Q
Maintenance Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Color of exhaust gas
Blue under light load w
When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low w
Check items

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for “Chg Air Press Sensor High (Low) Error. (*2)” See
*2 for failure code. q
Carry out troubleshooting for “Fuel Temp Sensor High (Low) Error. (*3)” See *3
for failure code. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

S-7 Exhaust smoke is black (incomplete combustion) 1

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


• Supply of fuel is excessive

• Defective condition of fuel spray
Clogged spill piping (on cylinder head side)

• There is overheating:

See “S-14 Coolant temperature becomes too high (Overheating)”

(limiting injection rate (output) because of an error in electrical system)
Improper fuel injection pressure

Improper fuel injection timing
• EGR valve is stuck and is open

(Excessive EGR gas, insufficient intake of air)
Crushed, clogged muffler
Abnormally worn injector

Clogged, seized injector
Stuck EGR valve
Degree of use of
Operated for long period E E E E E
machine
Suddenly became black w Q Q Q
Questions
Color of exhaust
Gradually became black w Q Q Q
gas
Black during light-load operation w
Oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temper-
Q w
ature of some cylinders is low
Check items

Torque converter stall occurred or pump relief speed is high (Fuel is injected
Q Q
excessively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w
Troubleshooting

When muffler is removed, exhaust gas color improves q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for
q q
failure code.
When a cylinder is cut out for reduced cylinder mode operation, engine
q
speed does not change
Inspect spill piping (on cylinder head side) directly q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error. (*3)”
q
See *3 for code.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

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

• Long-time operation of engine at low idle or high idle (Do not run engine
Worn, damaged valve (stem, guide, seal)

at idle for more than 20 minutes continuously)
• External leakage of oil
Oil leakage from EGR valve system

Dust sucked in from intake system
• Wear of parts in lubrication system
Clogged breather, breather hose

Worn seal at turbocharger end
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions
Operated for long period EEEE E

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

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

When intake manifold is removed, inside is found to be dirty abnor-
q
mally
Troubleshooting
Excessive play of turbocharger shaft q q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
S-9 Oil becomes contaminated quickly 1

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

• Entry of exhaust gas into oil due to internal wear
Defective seal at turbocharger turbine end

• Clogging of lubrication passage
• Use of improper fuel
• Use of improper oil
Clogged breather, breather hose

• Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Worn EGR valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use of
Operated for long period EEEE
Questions
machine
Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates error even when oil temperature is high (if moni-
w Q
tor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Blue under light load w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Troubleshooting

See S-7
Check breather and breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Cause

• Leakage of fuel
• Defective condition of fuel injection (fuel pressure, injection timing)
• Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of
Questions
Operated for long period EE E

machine
More than for other machines of same model Q Q Q Q
Condition of fuel con-
Gradually increased Q Q
sumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
w
Check items
Low idle speed is high Q

Torque converter stall occurred or oil pressure pump relief speed is high Q
Black Q Q Q Q
White Q
Remove and inspect head cover directly q

Inspect feed pump oil seal directly q
Troubleshooting
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting for “Coolant Temp Sens High (Low) Error. (*2)” See *2 for fail-
q
ure code.
Check with monitoring function of the machine monitor. q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Cause
Broken O-ring of cylinder liner, holes caused by pitting

• Internal leakage in lubrication system
• Internal leakage in cooling system
Insufficient amount of thrust by cylinder liner

Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
Questions
Degree of use of machine Operated for long period E E

Suddenly occurred Q Q
Increase of oil level
Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Troubleshooting Check items
There are excessive air bubbles in radiator, coolant spurts back w w
Pressure-tightness test of cylinder head shows there is leakage q

Inspect cylinder block, liner directly q q
Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
S-12 Oil pressure drops 1

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

• Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

• Defective oil pressure control
Defective oil level sensor, wiring harness

• Improper selection of oil (improper viscosity)
Leakage from EGR oil pressure piping

• Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Defective EGR oil pump

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

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
w
Maintenance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure
monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if monitor is Indicates pressure drop on slopes w
installed)
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve spring of oil pump relief valve is fatigued, damaged q

See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, leaks oil q
Inspect EGR oil pressure piping directly q
Carry out troubleshooting for “Eng Oil Press Sensor High (Low) Error. (*1)”
q
See *1 for failure code.
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
S-13 Oil level rises (Entry of coolant or fuel) 1

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

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

Cracked EGR cooler (Coolant in oil)
Defects in thermostat seat section

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Questions
Degree of use of
Operated for long period EE E
machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of
w Q
bubbles appear, or coolant spurts back
Check items
Exhaust smoke is white Q Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned up, water comes out w
Oil level in clutch or damper chamber of machine is low w
Oil level in hydraulic tank of applicable machine is low
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
q
out (*1)
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Cause

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Problem in coolant circulation system
• Rise in hydraulic oil temperature
External water leakage from EGR cooler
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
Operated for long period EEE EE
machine
Questions
Condition of over- Suddenly overheated Q Q w Q

heating Always tends to overheat Q w w Q
Coolant tempera- Rises quickly Q w
ture gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed)
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are clogged
w w
with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Inspect EGR cooler for leakage of coolant directly q
Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation test of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
S-15 Abnormal noise is made 1

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

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise before starting

troubleshooting.
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
a The engine is operated in the low-temperature mode while it is not
Leakage of air between turbocharger and cylinder head

warmed up sufficiently. Accordingly, the engine sound becomes a little
Broken dynamic valve system (valve, rocker lever)

larger. This does not indicate abnormality, however.
Interference of turbocharger, seized turbocharger

a When the engine is accelerated, it is operated in the acceleration mode
Crack of or gas leakage from EGR gas piping

and its sound becomes a little larger for up to about 3 seconds. This does
not indicate abnormality, however.
Removed, seized gear train bushing

Improper gear train backlash
Clogged, seized injector

Dirt caught in injector
Degree of use of Operated for long period E
Questions
machine
Condition of Gradually occurred Q Q
abnormal noise Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of w Q

Color of exhaust Blue under light load w
gas Black Q w Q
Engine does not pick up smoothly and combustion is abnormal w
Abnormal noise is loud when engine is accelerated Q Q Q Q
Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q q
Abnormal noise is heard only when engine is started q
Check with monitoring function of the machine monitor q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
S-16 Vibration is excessive 1

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

• Defective parts (abnormal wear, breakage)
• Misalignment between engine and chassis
• Abnormal combustion
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

a If abnormal noise is made and vibration is excessive, carry out troubleshoot-
Worn main bearing, connecting rod bearing

ing for “S-15 Abnormal noise is made”, too.

Improper gear train backlash
Broken parts inside damper

Worn camshaft bushing
Degree of use of
Questions
Operated for long period E E E

machine
Condition of Suddenly increased Q Q
vibration Gradually increased Q Q Q
Metal particles are found when oil filter is drained w w
a Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Check with monitoring function of machine monitor q
Inspect engine mounting bolts and cushions directly q
When alignment is measured, radial runout or facial runout is detected q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Remedy
UEN02653-00
PC450/LC/LCD/LCHD-8
© 2007 KOMATSU
All Rights Reserved
28
UEN02654-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools ...............................................................................................................................11
UEN02654-00 50 Disassembly and assembly
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The [Removal] section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q General tools that are necessary for removal
q Also the following information is described are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in the Removal Section
tuted and should always be used are explained and listed below.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
N: Tools newly developed for this 6 : This mark shows the amount of oil or coolant
model. They respectively have a to be drained.
new part number. 4 : Weight of part or component
R: Tools with upgraded part numbers.
They are remodelled from already
available tools for other models.
Installation
Blank: Tools already available for other
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the reverse order of
removal.
3) Circle mark Q in sketch column:
q Instructions and precautions for installing parts
q The sketch of the special tool is pre-
are shown with [*1] mark in the Installation
sented in the section of "Sketches of
Section, identifying which step the instructions
special tools".
are intended for.
q This mark means part No. of special
q General tools that are necessary for installa-
* *** ****
tools starting with 79 T- -
and that they can not be supplied
tion are described as [1], [2]•••etc. and their
part names, part numbers and quantities are
from Komatsu in Japan (i.e. locally
not described.
made parts).
q Marks shown in the Installation Section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
50 Disassembly and assembly UEN02654-00
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for disassembly or assembly of parts coolant drained are described.
are described as A1,•••X1 etc. and their q General tools that are necessary for disassem-
part names, part numbers and quantities bly are described as [1], [2]•••etc. and their part
are described in the special tool list. names, part numbers and quantities are not
q Also the following information is described described.
in the special tool list. q The meanings of the symbols used in Disas-
1) Necessity sembly section are as follows.
t : Special tools that cannot be substi- k : This mark indicates safety-related precau-
tuted and should always be used tions that must be followed when imple-
(installed). menting the work.
q : Special tools that will be useful if avail- a : Know-how or precautions for work
able and are substitutable with com- 6: Quantity of oil or coolant drained
mercially available tools.
2) Distinction of new and existing special
tools
N : Tools newly developed for this Assembly
model. They respectively have a q In Assembly section, the work procedures, pre-
new part number. cautions and know-how for carrying out those
R : Tools with upgraded part numbers. procedures, and quantity of the oil and coolant
They are remodelled from already added are described.
available tools for other models. q General tools that are necessary for assembly
Blank : Tools already available for other are described as [1], [2]•••etc. and their part
models. They can be used without names, part numbers and quantities are not
any modification. described.
3) Circle mark Q in sketch column: q The meanings of the symbols used in Assem-
q The sketch of the special tool is pre- bly section are as follows.
sented in the section of "Sketches of k : Precautions related to safety in execution
special tools". of work
q This mark means part No. of special a : This mark gives guidance or precautions
* *** ****
tools starting with 79 T- -
and that they can not be supplied
when doing the procedure.
2 : Type of coating material
from Komatsu in Japan (i.e. locally 3 : Tightening torque
made parts). 5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene, poly-
propylene, tetrafluoroethylene and vinyl chlo-
20 g Polyethylene
LT-1B 790-129-9050 ride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holts MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resist-
Gasket sealant
ant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resist-
LG-8
ant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

compound
prevention
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
400 g x Caution:
Molybdenum SYG2-400M 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 20 Can • The grease should be applied to work equipment
16 kg pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since colour is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
Special tools list 1
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)

q ........... Extremely useful if available or can be substituted with commercially available
part
a New/Remodel: N............ Tools with new part numbers, newly developed for this model
R:........... Tools with upgraded part numbers, remodelled from items already available for
other 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
Sketches of special tools).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
1 795-630-5500 Standard puller t 1

Fuel supply pump 2 01010-81080 Bolt t 2 Removal of fuel supply pump
3 01643-31032 Washer t 2
4 795-931-1100 Seal puller assembly q Removal of rear oil seal
5 795-931-1210 Sleeve jig tool t 1
Rear oil seal A 6 795-931-1220 Sleeve jig tool t 1
Press fitting of rear oil seal
7 01050-31645 Bolt t 3
8 01050-31625 Bolt t 3
Angle tightening of
9 790-331-1110 Wrench q 1
bolt
Engine valve Adjustment of engine valve
10 795-125-1360 Clearance gauge q 1
clearance clearance
Removal, installation of engine
Engine and B 796T-601-1110 Stopper t 1 Q
mounting bolt
hydraulic pump
796-460-1210 Oil stopper q 1
assembly C Stopping of oil
796-770-1320 Adapter q 1
1 796T-627-1630 Push tool q 1 Q Removal of shaft
2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
790-101-5401 Push tool kit t 1
790-101-5531 • 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
New/remodel
Necessity
Symbol
Sketch
Q'ty
796-627-1210 Wrench assembly t 1

796-627-1220 • Wrench 1 Removal, installation of round
1
796-427-1140 • Pin 3 nut
01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
Final drive 791-122-1130 Plate q 1
E
assembly 790-101-2550 Leg q 2
2 790-101-2740 Adapter q 2 Pressing of bearing inner race
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 t}) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1 Installation of floating seal
Carrier roller 1 791-430-3230 Installer t 1
F
assembly 2 791-601-1000 Oil pump t 1
Track roller 1 791-630-1780 Installer t 1
G
assembly 2 791-601-1000 Oil pump t 1
1 791-575-1520 Installer t 1
Idler assembly H
2 791-601-1000 Oil pump t 1
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
Disassembly, assembly of
1 Cylinder
790-101-1600 t 1 recoil spring assembly
(686 kN {70 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
791-650-3000 Remover and installer t 1
Track shoe Cylinder
K 790-101-1300 t 1 Pulling out of master pin
assembly (980 kN {100 t})
790-101-1102 Pump t 1
New/remodel
Necessity
Symbol
Sketch
Q'ty
796-946-1310 Guide Ø21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide Ø20.9
1 1
(For 723-46-44100)
796-946-2210 Guide Ø20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide Ø21.6
1
(For 723-46-42800)
2
Control valve 796-946-2120 Guide Replacement of pressure
L 1
assembly (For 723-46-44100) compensation valve seal
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500)
796-946-1330 Sleeve
1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve
1
(For 723-46-42800)
3
796-946-2130 Sleeve
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
Centre swivel joint Disassembly, assembly of cen-
M 790-101-2540 • Washer 1
assembly tre swivel joint assembly
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 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 piston
2
790-102-4310 Pin t 2 assembly
3 790-720-1000 Expander q 1
Ring (For boom and
796-720-1680 q 1
bucket)
Clamp (For boom and Installation of piston ring
4 07281-01589 q 1
bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
• 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
Ø120
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
Operator cab glass 2 793-498-1210 Lifter (Suction cup) t 2 Installation of operator cab
X
(stuck glass) 3 20Y-54-13180 Stopper rubber t 2 glass (stuck glass)
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
B. Stopper
D1. Push tool
D7. Push tool
E2. Push tool
UEN02654-00

© 2007 KOMATSU
All Rights Reserved
14
UEN02655-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 6
Removal and installation of engine front seal ............................................................................................... 12
Removal and installation of engine rear seal ................................................................................................ 13
Removal and installation of cylinder head assembly .................................................................................... 16
Removal and installation of radiator assembly ............................................................................................. 25
Removal and installation of hydraulic oil cooler assembly ............................................................................ 27
Removal and installation of aftercooler assembly......................................................................................... 29
Removal and installation of engine and hydraulic oil pump assembly .......................................................... 30
Removal and installation of fuel 8. Disconnect return hose (8) of the fuel supply
supply pump assembly 1 pump.
9. Disconnect the intake air heater harness clamp
(9) and fuel supply pump connectors PV1 (10),
Special tools PV2 (11) and G (12).
10. Remove the fuel supply pump high-pressure
Necessity
pipe clamp (13) and 2 boots (13A). [*1]
Symbol
Sketch
Q’ty
N/R
Part number Part name a Common rail side not visible sheltered by
the fuel filter.
1 795-630-5500 Standard puller t 1
A 2 01010-81080 Bolt t 2
3 01643-31032 Washer t 2
Removal
k Disconnect the negative (–) terminal of battery.
1. Open the engine inspection cover.
2. Remove undercover (radiator, engine).
3. Remove cover (1).
4. Remove fan guard (2).
5. Remove air intake hose (3).
11. Remove 2 high-pressure pipes (14) at the fuel

supply pump outlet port. [*2]
6. Loosen adjustment nut (5) and locknut (6) and

remove V-belt (7) from the pulley.
7. Disconnect harness connector (M34), remove
the bracket mounting bolts, remove air condi-
tioner compressor assembly (4) and deposit 12. Disconnect inlet tube (15) of the fuel supply
them on the floor cover. pump. [*3]
13. Disconnect feed pump inlet tube (16) and out- 16. Remove nut (21) and washer (22).
let tube (17) to remove lubrication tube (18). a Take care not to drop the removed parts
into the gear case. [*4]
14. Remove fuel supply pump bracket (19) from

the engine bottom. 17. Setting the tools
1) Insert the bar into the fan pulley round hole
(a) and rotate the crankshaft normally.
a Rotate by tightening the fan belt or
pressing hard on the mid section of
the V-belt.
15. Remove cover (20) on the side of timing gear

case.
2) Align the tapped hole (hole for inserting 18. Remove the fuel supply pump mounting bolts
the removal bolt) of supply pump drive (23). Press the shaft of the pump using a tool and
gear to the mounting bolt hole of the cover remove the fuel supply pump assembly (24). [*5]
(cover (20) removed in step 15). a Take care not to drop the pump.
a Rotate the crankshaft to about the a Leave the tool applied until the pump is
middle (a) between the damper 2- installed next. [*6]
5TOP and 3-4TOP and then inch the
crankshaft until correctly aligned to
the bolt hole.
a If the tapped hole on the drive gear
does not appear, rotate the crankshaft
one more round.
3) Set tools A1, A2 and A3.
Installation
a Carry out installation in the reverse order to
removal.
[*1]
Tighten clamp (13) with the hand first, and then
tighten it permanently.
3 Clamp mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*2]
Install high-pressure tube (14) by tightening by
hand, then tighten it permanently.
3 Sleeve nut of the high-pressure tube:
Common rail side:
39.2 – 58.8 Nm {4 – 6 kgm}
Pump side: 39.2 – 49 Nm {4 – 5 kgm}
a Face the common rail side slit of the splash
prevention cover downward and the supply
pump side slit toward the cylinder block.
[*3]
3 Joint bolt of tube (15):
25.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
a Match the key and keyway to install.
[*5]
3 Joint bolt of pump side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
2 Mounting bolt: Gasket sealant (LT-2)
q Fuel leak check

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

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

sub-tank (2). 7. Remove the clamp and disconnect hose (9)
between the radiator and the engine at the
5. Remove the mounting bolt and then hoist the radiator side. [*2]
engine hood assembly (3) to remove. 8. Remove covers (6), (7), and fan guard (8).
4 Engine hood: 200 kg
9. Remove oil filter (10). (Leave the tube unre-

moved)
10. Remove fuel pre-filter (11).

(after disconnecting the hose, put it at the left
side of the engine)
11. Remove priming pump (12).
(after disconnecting the hoses, let each hose
put on the left-hand side of the engine)
12. Remove fuel main filter (13).

(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine. [*3]
16. Remove clamp (23), bolts (24) and bracket (25)

to remove the housing complex (diffuser) (26).
13. Disconnect the terminal of intake air heater

harness (14).
a Disconnect the clamp.
14. Remove the air intake connector (15).
17. Disconnect injector harness connectors (27) (at 6

places), remove the clamp and shift the harness
to the lower left-hand side of the engine.
a For how to remove the connector, see the
“Removal and installation of cylinder head
15. Disconnect the connector EGR (16), SEGR assembly”.
(17), TIM (boost temperature) (18), PIM (boost 18. Remove clamps (28) and boots (29).
pressure sensor) (20), PAMB (atmospheric 19. Remove the clamp and 6 high-pressure injec-
sensor) (21), connector (22), and wiring clamp tion tubes (30). [*5] [*6]
(19).
a Remove harness clamps.
a Place removed parts together under the
engine. [*4]
20. Remove head cover (31). [*7] 23. Remove holder mounting bolt (40) of injector
(39) and then remove injector (39) along with
holder (41). [*10]
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
21. Removal of injector harness.

1) Fully loosen 2 capture nuts (33) on the
head of injector (32). [*8]
a Loosen nuts alternately.
2) Loosen bolt (34) of harness fixing holder.
[*9]
22. Removal of rocker arm assembly (35).

1) Loosen locknut (36) and then loosen
adjustment screw (37).
2) Remove mounting bolt (38) and then
rocker arm and shaft assembly (35).
Installation q Install high-pressure tubes between the com-

a Carry out installation in the reverse order to mon rail and fuel injector according to the fol-
removal. lowing instructions:
1) Install high-pressure pipes (70), (71), (72),
[*1] (73), (74) and (75).
3 Hose clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm} a Mounting angle of the high-pressure
injection pipe is adjusted when the
[*2] injector is installed.
3 Radiator-related hose clamp 3 Sleeve nut (on both sides):
(9): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 39.2 – 49 Nm {4 – 5 kgm}

2) Install bracket (76) and clamp (77) and
[*3] tighten by hand first, and then tighten
3 Fuel filter joint bolt: them permanently.
3 Mounting bolt:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Install clamps (78), (79), (80) and (81).
[*4]
4) Install 6 each splash prevention covers
Keep the harness assembly and other harnesses 10 (82) and (83).
mm and above away from the high-pressure tube. a Direct the slit on the injector side
downward and that on the common
[*5] rail side toward the cylinder block.
k Don't correct high-pressure tube by bend- 5) Install bracket (84).
ing it for re-use. 3 Mounting bolt:
k Always use genuine clamp for fixing high- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
pressure pipe. Strictly observe the tighten- 6) Install clamps (78), (79), (80) and (81).
ing torque requirements. 3 Mounting bolt:
k Keep the harness assembly and other har- 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
nesses 10 mm and above away from the
high-pressure tube.
[*6]
Check the following matters before installing high-
pressure pipe. If there is any abnormality, replace
the high-pressure tube to prevent possible fuel
leakage.
q Check the taper seal portion (between the tip

of section (a) and 2 mm from the end) of the
joint section for any vertical slit (b) and/or dent
(c) visually recognizable.
q Check part (d) (from the tip of the taper seal
portion to 2 mm from the end) for any stepped
wear (fatigue) your finger nail may catch.
2) Install gasket (91) and O-rings (92) and (93) to

injector (85).
2 O-ring: Engine oil (EO30)
[*7]
3 Head cover mounting bolt
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
3) Insert holder (87) to injector (86). While holding
[*8] them in this state, insert inlet connector (90) to
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm} the locker housing toward the high-pressure
pipe insertion hole.
[*9]
Tighten the mounting bolt of harness holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
[*10]
Check that the inside of the injector sleeve is free
from dirt.
1) Loosen the mounting bolt of common rail (85).
4) Fit the ball washer to bolt (88) and tighten

holder (87) temporarily.
2 Spherical part of washer:
Engine oil (EO30)
5) Locate high-pressure sleeve (89) to inlet con-
nector (90) and then tighten them temporarily.
a Tighten the common rail side sleeve nut
temporarily, too.
6) Tighten holder (87) permanently using bolt
(88).
a Tighten bolt while pulling the tube of the
high-pressure pipe in the opposite direc-
tion to the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the high-
pressure sleeve from the inlet connector and
then install the other injectors sequentially by
following the above procedure.
8) Tighten the common rail mounting bolt.

3 Common rail mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
q Feed coolant
Feed coolant from the radiator coolant filler to
the specified level. Start the engine and allow
the coolant to circulate the piping. Check the
coolant level.
q Fuel leak check

Refer to the paragraph on the “Checking fuel
circuit for leakage” in Testing and adjusting
section, and check the fuel system for any
leakage accordingly.
q Air bleeding
Refer to the paragraph on the “Bleeding air
from fuel circuit” in Testing and adjusting, and
bleed the air accordingly.
Removal and installation of 6. Remove fan belt (7) and the air compressor
engine front seal 1 belt (8).
7. Sling the damper and pulley assembly (9) and
then remove it by loosening 6 mounting bolts.
Removal
4 Damper and pulley assembly: 25 kg
1. See the paragraphs for the “Removal and
installation of radiator”, “Removal and installa- 8. Remove front seal.
tion of hydraulic oil cooler”, and “Removal and
installation of aftercooler” to remove the radia-
tor, hydraulic oil cooler and the aftercooler.
2. Remove covers (1) and fan guard (2).
Installation
q Carry out installation in the reverse order to
removal.
3. Loosen the air compressor assembly mounting
bolts and loosen adjustment nuts (3). Using the push tool (outside diameter 120 mm),
4. Loosen alternator assembly adjustment nuts press fit front oil seal to the cover.
(4) and adjustment bolt guide (5). a Oil seal press-fit margin (a): 16 (+1/0) mm
2 Oil seal lip (50 – 80% of void lip space):
Grease (G2-LI)
5. Remove fan (6).
Removal and installation of 5. Removal of rear seal

engine rear seal 1 Removal of standard seal
Hitch the end of tool A4 to the metal ring of
seal (1) and pull out the seal with impacts of
Special tools slide hammer [1].
a Before pulling out the seal, drive it in a lit-
Necessity
tle to loosen adhesion between the seal
Symbol
Sketch
Q’ty
N/R
Part number Part name and housing (2) for the ease of removal.
a Do not use a drill, etc. since chips may
Seal puller enter the engine.
4 795-931-1100 q 1
assembly
5 795-931-1210 Sleeve jig t 1
A
6 795-931-1220 Sleeve jig t 1
7 01050-31645 Bolt t 3
8 01650-31625 Bolt t 3
Removal
1. Remove hydraulic pump assembly by reading
the paragraph for the “Removal and installation
of hydraulic pump assembly.”
2. Remove the damper.

Removal of sleeved seal
3. Sling the flywheel (2) by leaving a flywheel 1) Hitch the end of tool A4 to the metal ring
mounting bolt (1) unremoved. of seal (1) and pull out the seal with
impacts of slide hammer [1].
4. Sling the flywheel (2) to remove. a Before pulling out the seal, drive it in
4 Flywheel assembly: 60 kg a little to loosen adhesion between
the seal and housing for the ease of
k Since the sling [1] is held slanted when removal.
the flywheel is lifted, care be taken for 2) Cut and remove sleeve (3) with a chisel
the swinging of sling when the flywheel and a hammer.
assembly (2) is released. a Take care not to damage crankshaft
(4).
a Remove all the chips, if any.
Installation
removal.
Installation of rear seal

a Check the Teflon seal (Laydown lip seal) for
the wear of the shaft and install "Standard seal"
or “Sleeved seal”.
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw,
install the standard seal. In other cases, install
the sleeved seal.
a The left one in the following figure is the stand-
ard seal and the right one is the sleeved seal.
2) Hold the metal ring of seal (1) with both

hands and push it in firmly by applying
force equally.
Procedure for installing standard seal 3) After pushing in the seal, remove plastic
a Before installing the seal, check that the end inner cylinder (3).
corners and lip sliding surfaces of crankshaft a When removing the inner cylinder,
(4) are free from housing flaw, burr, sharp edge take care not to damage the seal lip.
and rust.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip (a). Wipe off oil
from the shaft.
a Never remove plastic inner cylinder (3) of the
standard spare seal before installing the seal.
1) Set the larger inside diameter side (b) of
plastic inner cylinder (3) to the end of
crankshaft (4).
a Take care not to mistake the direction
of the plastic inner cylinder.
4) Tighten the bolts (A7 and A8) evenly to

press fit seal (1) until the end of tool A5
reaches the end of crankshaft (4).
a First, tighten tool A5 until bolt A7 (45
mm under head) stops, then tighten
bolt A8 (25 mm under head).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the 2) Set the sleeve of the seal to the end of the
red sealant layer from its periphery. crankshaft, and then tighten the bolt A7
0
evenly to press fit sleeve and seal assem-
bly (2) until the end of tool A6 reaches the
end of crankshaft (4).
Procedure for installing sleeved seal

a Before installing the seal, make sure that the
end corners and lip sliding surfaces of crank- 3) Remove tool A6 and install tool A5.
shaft are free from housing flaws, burrs, sharp 4) Tighten the bolts A8 evenly to press fit
edges and rusts, etc. seal assembly (2) until the end of tool A5
a When installing the seal, do not apply oil or reaches the end of crankshaft (4).
grease to between shaft, sleeve (1), and seal a After press fitting the seal, remove the
lip (a). Wipe off oil from the shaft. red sealant layer from its periphery.
a Handle the seal and sleeve as an assembly
and don't separate them from each other.
1) Set the sleeve seal assembly (2) to tool A6.

2 Sleeve inner cylinder surface:
Gasket sealant (LG-7)
Removal and installation of 6. Remove clamp (4) and remove air intake tube
cylinder head assembly 1 (5). [*1]
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
A9 790-331-1110 Wrench q 1
A10 795-125-1360 Filler gauge q 1
Removal
1. Drain coolant.
2. Drain hydraulic oil. 7. Remove the clamp and disconnect hose (9)
6
between the radiator and the engine at the
Hydraulic oil: Approx. 248 l
radiator side. [*2]
3. Close the fuel stopper valve on the fuel tank.
8. Remove covers (6), (7), and fan guard (8).
4. Disconnect connector P24 and overflow tube
(1) and remove the sub-tank (2).
5. Remove the mounting bolt and then hoist the

engine hood assembly (3) to remove.
9. Remove the exhaust pipe cover (10) and the

muffler cover (11).
10. Remove clamp (12) and two clamps (13) of 15. Disconnect the terminal of intake air heater
muffler. Shift the muffler (14) to remove the harness (19).
joint tube (15) and the muffler (14). a Disconnect the clamp, too.
11. Remove oil filter (80). (Leave the tube unre-

moved) 17. Disconnect the connectors EGR (21), SEGR
(22), TIM (boost temperature sensor) (23), PIM
(boost pressure sensor) (25), PAMB (atmos-
pheric sensor) (26), connector (27), and wiring
clamp (24).
a Remove clamps.
a Place removed parts together under the
engine. [*4]
12. Remove the fuel pre-filter (16).

(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
13. Remove priming pump (17).
(after disconnecting the hoses, gather them to
the left-hand side of the engine.)
14. Remove the fuel main filter (18).
(Remove the tube clamp and allow the tube to
hang on the left-hand side of the engine.) [*3]
18. Remove clamp (28), bolt (29) and brackets 21. Remove clamp (34) and boots (35) to remove
(30) to remove the housing complex (diffuser) 6 high-pressure injection tubes (36). [*4] [*8]
(31).
19. Remove brackets (behind the front hanger)
(32).
20. Disconnect injector harness (33) and move it

to the lower left-hand side of the engine.
22. Remove the housing (41) by removing two

mounting bolts (38) from the side of air intake
manifold, two mounting bolts (39) from the side
of EGR valve and two mounting bolts (40) from
above. [*5]
a Disconnect fuel injector connector (c) with a
single action by inserting a flat-head screw-
driver [1] to the stepped portion (a), then mov-
ing the driver in the direction of (X) while
pressing stopper of (b).
23. Sling the air intake manifold assembly (42),

remove 24 mounting bolts to remove the 26. Remove tubes (45) (for taking out EGR exhaust
assembly. gas).
4 Air intake manifold: 25 kg
27. Remove EGR valve inlet tube cover (46).

24. Remove hose (43).
28. Remove exhaust manifold heat insulation covers 32. Remove spill tube (51). [*9]
(47).
33. Remove air vent tube (52). [*10]
29. Disconnect turbocharger lubrication inlet tube

(48) and disconnect the drain tube (49). [*6] 34. Remove head cover (53). [*11]
30. Sling the turbocharger and exhaust manifold 35. Removal of injector harness [*12]
assembly (50), and remove the mounting bolts. 1) Fully loosen two capture nuts (55) on the
[*7] head of injector (54).
a Loosen nuts alternately.
31. Remove turbocharger and exhaust manifold 2) Loosen bolt (56) of harness fixing holder.
assembly by hoisting.
4 Turbocharger and exhaust manifold
assembly: 40 kg
36. Removal of rocker arm assembly (57) [*13] 39. Remove 12 crossheads (65). [*15]
1) Loosen locknut (58) and then loosen
adjustment screw (59).
2) Remove mounting bolt (60) and then
rocker arm and shaft assembly (57).
40. Removal of injector harness connector

1) Remove mounting bolt (67) of harness
connector (66).
2) Remove holder (69) from the harness.
37. Remove 12 push rods (61).
3) Remove harness connector (70) by push-

38. Remove holder mounting bolt (63) of injector ing it outward from inside of rocker hous-
(62) and then remove injector along with ing (71).
holder (64). [*14] 4) Remove O-ring (72) from the rocker hous-
a Do not try to grip the solenoid valve at the ing.
top of the injector using a pliers and the
like.
41. Remove rocker housing (71). [*16] Installation

removal.
[*1]
3 Hose clamp: 9.8 ± 0.5 Nm {100 ± 5 kgcm}
[*2]
3 Radiator-related hose clamp:
3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
[*3]
3 Fuel filter joint bolt:
24.5 – 34.5 Nm {2.5 – 3.5 kgm}
42. Removal of cylinder head assembly [*17] [*4]

1) Remove each set of 7 mounting bolts (74) Keep the harness assembly and other harnesses
of cylinder head assembly (73). 10 mm and above away from the high-pressure
2) Using eyebolt [1], lift and remove cylinder tube.
head assembly (73).
4 Cylinder head assembly: 20 kg [*5]
Tighten the air intake manifold assembly mounting
3) Remove each head gasket. bolts in the order given below.
3 Intake manifold assembly:
59 – 74 Nm {6 – 7.5 kgm}
[*6]
3 Lubrication tube sleeve nut:
40 – 44 Nm {4.1 – 4.5 kgm}
[*7]
Tighten the exhaust manifold assembly mounting
bolts in the order given below, then tighten other
bolts.
3 Exhaust manifold assembly mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*13]
1) Loosen locknut, then install rocker arm and
rocker shaft assembly.
3 Rocker shaft mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Remove the cover and adjust the valve clear-
ance.
Pointer is located under the cover.
q Valve clearance
Intake : 0.33 mm
Exhaust : 0.71 mm
a See the paragraph of “Adjusting valve clear-
ance” in the part for Testing and adjusting for
the valve clearance instructions.
[*8] 3 Rocker arm locknut:
a For details on and how to install the high-pres- 58.8 – 73.5 Nm {6 – 7.5 kgm}
s u r e t u b e c o v e r, s e e P a r a g r a p h [ * 5 ] i n
"Removal and installation of fuel injector [*14]
assembly." For the mounting instructions of injector and holder,
see the paragraph for the "Removal and installation
High-pressure tube installation instructions of fuel injector assembly."
a Don't correct high-pressure tube by bending it
for re-use. [*15]
1) Tighten high-pressure tube permanently. a Amply apply engine oil (EO30-CD) to cross-
3 Sleeve nut: head guide and crosshead top face.
39.2 – 49 Nm {4 – 5 kgm} a Adjust the crosshead according to the follow-
2) Temporarily tighten high-pressure clamp and ing procedure.
brackets all by hand. 1) Loosen the locknut and return the adjust-
3) Tighten high-pressure tube clamp perma- ment screw.
nently. 2) Holding the top of the crosshead lightly,
3 Clamp nut: tighten the adjustment screw while keep-
11.8 – 14.7 Nm {1.2 – 1.5 kgm} ing the crosshead in contact with the valve
4) Tighten bracket permanently. stem.
5) Install cover. 3) After the adjustment screw touches the
a Direct the slit to the side of cylinder head. valve stem, tighten it further by 20°.
6) Temporarily install gate-type bracket and cover 4) Tighten the locknut at this position.
3 Locknut:
(also working as clamp).
7) Tighten the cover permanently. 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
3 Cover mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm} [*16]
3 Rocker housing mounting bolt:
8) Tighten the gate-type bracket permanently.
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*9]
3 Spill tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*10]
3 Air vent tube: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*11]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*12]
a Tighten the capture nuts alternately.
3 Capture nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
[*17] a When not using tool A9

a Clean the bottom face, block top face and liner After applying a paint marking to the cylinder
with dry cloth or soaked with a solvent. head and bolt, tighten the bolt by 90° to 120°
a Replace a bolt having 5 punch marks to the (target 120°).
bolt head. a After tightening bolts 1 – 6, tighten auxiliary
a Tighten the bolt with hand and screw in to the bolt 7.
block by turning the bolt at least 2 rounds. 3 Cylinder head mounting auxiliary bolt:
2 Bolt threaded portion and under side of 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
the bolt head:
LM-P or engine oil (EO30-CD) a After tightening the bolt, punch a mark on its
a Tighten the cylinder head mounting bolts in the head.
order indicated in the figure. a When using a new bolt, do not punch a mark
3 Cylinder head mounting bolt 1 – 6: on its head.
1st time: 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time: 166.6 – 176.4 Nm {17 – 18 q Feed coolant
kgm} Feed coolant from the radiator coolant filler to
3rd time: Tighten bolt to 90 to 120° the specified level. Start the engine and allow
(target 120°) using tool A9. the coolant to circulate the piping. Check the
coolant level.
Removal and installation of 5. Remove the clamp and hoses (6), (7), (8) and
radiator assembly 1 (9) between the radiator and the engine. [*1]
6. Remove radiator front cover (10).

Removal
1. Remove covers (1) and (2).
7. Remove undercover.
2. Drain coolant. 9. Disconnect the lower hose (12).
3. Disconnect connector (P24) and overflow tube
10. Remove 2 upper mounting bolts (13).
11. Lift and remove radiator assembly (14). Installation

4 Radiator assembly: 30 kg q Carry out installation in the reverse order to
removal.
q Feed coolant
coolant level again.
[*1]
3 Radiator-related hose clamp
(8) : 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(7) : 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
(6) : 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
Removal and installation of

hydraulic oil cooler assembly 1
Removal
k Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
2. Remove cover under the hydraulic oil tank

drain plug. Remove the hydraulic oil tank drain
hose plug to drain hydraulic oil.
a Open the hydraulic oil tank cap before 6. Remove tube (8).
draining to release the tank inner pres- a Remove drain plug (7) and then remove
sure. Then drain oil from the cooler hose. fuel tube (8) after draining oil inside.
3. Disconnect connector P24 and overflow tube

7. Remove 3 hydraulic oil cooler left-side mount- Installation

ing bolts (9) and remove a hydraulic oil cooler q Carry out installation in the reverse order to
front mounting bolt (10). removal.
8. Remove 4 butterfly screws (11) from the
screen. q Oil fill (hydraulic oil tank)
9. Disconnect upper piping (12). Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circu-
late the piping. Check the coolant level again.
10. Remove net on the hydraulic oil cooler side.
11. Hoist to remove hydraulic oil cooler assembly.

4 Hydraulic oil cooler assembly: 45 kg
Removal and installation of 9. Extract hoses (9) and (10) from the cooler
aftercooler assembly 1 while pushing down the aftercooler assembly
(8). [*1]
10. Hoist the cooler assembly with nylon slings,
Removal etc. before the hose is completely extracted.
1. Open the radiator front cover. Withdraw the hose and pull out the aftercooler
2. Remove undercover (1). assembly sideway to remove.
4 Aftercooler assembly: 25 kg
3. Remove cover (2) under the aftercooler.
Installation
removal.
[*1]
Tightening torque procedure
1) Adjust the bridge position so that it will come
under the bridge band as shown in the figure
below.
2) Tighten till dimension (a) being 8 to 10 mm.
3) Tighten with a torque of 16 – 17 Nm (1.6 – 1.7
kgm).
4. Remove evaporator (3) with the bracket as a
unit.
5. Remove plate (4).
6. Remove grease gun holder (5).
7. Loosen hose clamp (6).
8. Remove mounting bolt (7).
a: Dimension
b: Lapped portion of bridge and band
c: Bridge
d: Punch hole
a Apply lubricant (Three-Bond band 18B) to the
threaded portion and tighten the bolt.
Removal and installation of 3. Close the fuel stopper valve on the fuel tank.
engine and hydraulic oil pump
4. Disconnect connector (P24) and overflow tube
assembly 1 (1) and remove the sub-tank (2).
Special tools 5. Remove the mounting bolt and then hoist the
Necessity
4
Symbol
Sketch
Engine hood: 200 kg
Q’ty
N/R
B 796T-601-1110 Stopper t 1 Q
1 796-460-1210 Oil stopper q 1
C
2 796-770-1320 Adapter q 1
Removal
k Disconnect the negative (–) terminal of bat-
tery.
k Completely ground the work equipment.
Loosen the hydraulic oil tank cap gradually
after stopping engine to release internal
pressure of hydraulic oil tank.
a Take care not to mistake installation position of
each piping by attaching tags, etc.
1. Drain coolant.
2. Remove hydraulic oil tank strainer and stop oil
using tool C.
a When not using tool C, remove the drain
plug and drain oil from hydraulic oil tank
and the piping.
6. Remove floor cover (4) on the control valve.

a Remove cover (4) to remove the following
covers (5) through (8).
7. Remove covers (5), (6), (7) and (8). 10. Disconnect hose (15) under the radiator.
a After removal, place the floor cover to
original position and temporarily tighten
the bolt.
11. Disconnect hoses (16), (17) and (18) on the

radiator and overflow hose (19). [*1]
8. Open the cover beside the pump and remove

covers (9), (10) and (11) on the pump side and
the floor cover (12) on the pump.
a Remove in the order of (9) to (12).
12. Remove two sound absorbing cover (20), 2

covers (21) and fan guard (22).
9. Remove undercovers (13) and (14).
13. Remove fan (23). 17. Remove the terminal of intake air heater har-
ness (29) and clamps (30).
14. Remove air intake tube (24) along with the

hose as a unit. [*2]
19. Remove fuel hose (pump – tank) (32), (33) and
fuel supply hose (tank – block) (34).
15. Loosen adjustment nut (25) and locknut (26)

and remove V-belt from the pulley. [*3]
16. Disconnect harness connector M34, remove

the bracket mounting bolts, remove air condi-
tioner compressor (28) and deposit them on
the floor cover.
20. Remove engine controller cover (35). 25. Disconnect return hose (41) and the clamp.
a Attach fuel stopper plug to the hose.
21. Disconnect engine controller connectors CE02

(36) and CE03 (37). [*4] 26. Disconnect the turbocharger hose (42).
22. Remove harness clamp (38) at two locations. 27. Disconnect the car heater hose (43).
23. Remove grounding T11 (39).
24. Disconnect oil level sensor connector P44
(40).
28. Disconnect alternator wiring B (44), R (45) and 32. Remove grounding harness (51) (between
E (46). engine and frame).
29. Disconnect the car heater hose (47).
33. Remove hydraulic pump piping.

30. Remove harness clamps (48) at 3 locations q (52) EPC source pressure port hose
and grounding T12 (49). (Collar band: Yellow)
q (53) Rear pressure port hose
(Collar band: Yellow)
q (54) Rear pump discharge port hose
q (55) Front pump discharge port hose
q (56) Drain port hose
q (57) Front negative pressure input port hose
q (58) Rear negative pressure input port hose
(Collar band: Red)
q (59) Front pressure input port hose
q (60) Pump suction port tube
34. Disconnect pump wiring connector at two loca-

tions.
q (61) V22 (PC-EPC solenoid valve)
31. Disconnect starter terminal B (50) and M7 con- (Collar band: Red)
nector. q (62) V21 (LS-EPC Solenoid valve)
(Collar band: White)
36. Hoist to remove engine assembly (64).

a Remove after checking that wiring, piping
clamps, etc. are disconnected without
omission.
4 Engine, hydraulic pump assembly:
1,700 kg
35. Using tool B, remove 4 engine mount bolts

(63) in front and rear. [*5]
a Easier to remove if nuts are heated by
gas.
Installation
removal.
[*1]
3 Hose clamp:
(18) 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(17) 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
(16) 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
[*2]
3 Hose clamp:
9.8 ± 0.5 Nm {100 ± 5 kgcm}
[*3]
a See the paragraph for the “Checking and
adjusting air conditioner compressor belt ten-
sion” in Testing and adjusting or the paragraph
for the "Removal and installation of engine
front seal".
[*4]
3 Connector screw:
2.82 ± 0.28 Nm {0.288 ± 0.035 kgm}
[*5]
3 Engine mount bolt:
824 – 1030 Nm {84 – 105 kgm}
q Feed coolant
q Oil feed (hydraulic oil tank)

Feed oil from the oil filler port to the specified
level. Start the engine and allow the oil to circu-
late the piping. Check the oil level again.
q Air bleeding
Refer to the paragraph on the "Bleeding air
from various parts" in Testing and adjusting.
UEN02655-00

© 2007 KOMATSU
All Rights Reserved
38
UEN02656-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Power train
Removal and installation of final drive assembly ............................................................................................ 2
Disassembly and assembly of final drive assembly........................................................................................ 3
Removal and installation of swing motor and swing machinery assembly ....................................................11
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 12
Removal and installation of swing circle assembly ....................................................................................... 19
Removal and installation of final 4. Remove the 24 mounting bolts and lift off the
drive assembly 1 final drive assembly (6). [*1]
a Take care extremely not to damage the
nipple sealing faces of the hose joints.
Removal a When slinging the final drive assembly, do
1. Remove the sprocket. For details, see not use the tap hole for the cover.
“Removal and installation of sprocket”.
k Lower the work equipment to the 4 Final drive assembly: 700 kg
ground and stop the engine. Then,
loosen the hydraulic oil filler cap
slowly to release the internal pressure
of the hydraulic tank.
Installation
removal.
[*1]
3. Disconnect drain hose (2), travel speed selec- 3 Mounting bolt:
tor hose (3), and motor hoses (4) and (5). 490 – 608 Nm {50 – 62 kgm}
a Remove the nipples, too.
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
q Bleeding air
See Testing and adjusting, “Bleeding air from
various parts”.
Disassembly and assembly of 2) Using eyebolt [2], remove cover (1).

final drive assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R

796-627-1220 • Wrench 1
1
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1 3. Spacer
791-122-1130 Plate q 1 Remove spacer (2).
E
790-101-2550 Leg q 2
2 790-101-2740 Adapter q 2
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (30 tons) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1
Disassembly
1. Draining oil
Remove the drain plug to drain the oil from the
final drive case. 4. No. 1 carrier assembly
6 Final drive case: Approx. 11 l 1) Remove No. 1 carrier assembly (3).
2. Cover
1) Place the final drive on block [1] and
remove the mounting bolts.
2) Disassemble the No. 1 carrier assembly 7. No. 2 carrier assembly

according to the following procedure. 1) Sling No. 2 carrier assembly (15) with
i) Push in pin (5) to drive out shaft (6) wires, etc. and remove it.
from carrier (7).
a After removing the shaft, remove
pin (5).
ii) Remove thrust washer (8), gear (9),
bearing (10), and thrust washer (11).
2) Disassemble No. 2 carrier assembly

i) Push in pin (16) to drive out shaft (17)
from carrier (18).
a After removing the shaft, remove
5. Sun gear pin (16).
Remove spacer (4), No. 1 sun gear (12), and ii) Remove thrust washer (19), gear
No. 2 sun gear (13). (20), bearing (21), and thrust washer
(22).
6. Thrust washer
Remove thrust washer (14) from No. 2 carrier 8. Nut
assembly (15). 1) Remove lock plate (23) from locknut (24).
2) Using tool E1, remove locknut. ii) Remove floating seal (27) from hub
(32).
9. Hub assembly
1) Using eyebolts [3], remove hub assembly iii) Remove bearings (28) and (29).
(25) from the travel motor.
3) Remove floating seal (30) from travel

2) Disassemble hub assembly (25) accord- motor (31).
ing to the following procedure.
i) Remove bearing (26) from hub (32).
4) Using puller [4], remove bearing (34) and

collar (33) together.
a You can remove bearing (34) and col-
lar (33) without using puller [4] in
some cases.
3) Install collar (33) and bearing (34) to travel

motor (31).
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
engine oil before installing.
1. Hub assembly
1) Using the push tool, press fit bearings (28)
and (29).
4) Using tool E3, install floating seal (30)

(which is hidden and not seen behind tool
E3) to travel motor (31).
a Thoroughly degrease and dry the O-
ring and O-ring fitting surface of the
floating seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding sur-
faces.
2) Using tool E3, install floating seal (27) to

hub (32).
a Thoroughly degrease and dry the O-
ring and O-ring fitting surface of the
floating seal before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding sur-
faces.
5) Using eyebolts [3], set hub assembly (25) 6) Under the condition in 5) above, measure
to the travel motor. Using the push tool, dimension (a).
lightly hit the bearing to press fit it.
7) Measure thickness (b) of nut (24).

2. Nut 8) Obtain (a) – (b) = (c).
Install the nut according to the following proce- 9) Using tool E1, tighten nut (24) until dimen-
dure. sion (c) is as follows.
1) Rotate the hub 2 – 3 turns. a Dimension (c): c +0.07–0.03 mm
2) Using tool E2, press the bearing inner race.
a Pressing force: 29.4 – 38.3 kN {3.0 –
3.9 t}
3) While the bearing is pressed, rotate the
hub at least 5 turns in 1 direction.
4) Release the pressing force.
5) Press the bearing again.
a Pressing force: 14.7 – 18.6 kN {1.5 –
1.9 t}
10) Using push-pull gauge [5], measure the

tangential force of the hub in its revolving
direction on the motor case.
a Tangential force: Max. 765 N {78 kg}
a The tangential force means the maxi-
mum force at the beginning of rota-
tion.
11) Install lock plate (23), fitting it to the motor a After assembling the carrier assem-
spline. bly, check that the gear (20) turns
2 Threads of mounting bolt: smoothly.
Adhesive (LT-2)
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
2) Install No. 2 carrier assembly (15).

a Install No. 2 carrier assembly (15) so
that the 4 gear shaft ends will be in
3. No. 2 carrier assembly the 4 hollows at the motor case end.
1) Assemble the No. 2 carrier assembly
a There is a caulking mark made when
the pin was inserted at the end of car-
rier side hole (h) and the inside wall of
the hole is swelled at that mark. Flat-
ten the swelled part in advance.
i) Install bearing (21) to gear (20) and fit
top and bottom thrust washers (19)
and (22), and then set the gear
assembly to carrier (18).
4. Thrust washer
Install thrust washer (14) to No. 2 carrier
assembly (15).
ii) Aligning the pin holes of shaft (17)

and carrier, lightly hit the shaft with a
plastic hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care
not to damage the thrust wash-
ers.
iii) Insert pin (16).
a After inserting the pin, caulk the
pin part of the carrier.
5. No. 2 sun gear ii) Aligning the pin holes of shaft (6) and
Install spacer (4) and No. 2 sun gear (13). carrier, lightly hit the shaft with a plas-
tic hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care
not to damage the thrust wash-
ers.
iii) Insert pin (5).
a After inserting the pin, caulk the
pin part of the carrier.
a After assembling the carrier
assembly, check that the gear (9)
turns smoothly.
6. No. 1 carrier assembly

a There is a caulking mark made when
the pin was inserted at the end of car-
rier side hole (h) and the inside wall of
the hole is swelled at that mark. Flat-
i) Install bearing (10) to gear (9) and fit
top and bottom thrust washers (8)
an d ( 11) , an d th en set t he ge ar
assembly to carrier (7). 2) Install No. 1 carrier assembly (4).
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).
8. Spacer
Install spacer (2).
9. Cover
Using eyebolts [2], install cover (1) and tighten
the mounting bolts.
2 Cover mounting face:

3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
q Refilling with oil

a Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely
cold district) through the oil filler.
5 Final drive case: Approx. 11 l
a After installing the final drive assembly to
the chassis, check the oil level again at
the specified position.
Removal and installation of swing 3. Lift and remove swing motor and swing
motor and swing machinery machinery assembly (6).
a When lifting the swing motor and swing
assembly 1 machinery assembly for removal, do so
slowly so that the hoses and other parts
Removal will not be damaged.
k Release the residual pressure in the a Take good care, when lifting the assembly,
hydraulic circuit. Refer to the “Releasing until the spigot joint portion is pulled out.
residual pressure from hydraulic circuit”
4
section in the Testing and adjusting chap- Swing motor and swing machinery
ter of this manual. assembly: 550 kg
for oil filler cap on the fuel tank to release
the residual pressure inside the tank and
move the work equipment lock lever to the
LOCK position.
1. Disconnect five swing motor hoses (1) through

(5).
q (1): Between swing motor and control
valve (MA port)
q (2): Between swing motor and control
valve (MB port)
q (3): Suction hose (S port)
q (4): Drain hose (T port)
q (5): Swing brake releasing pilot hose (B
port)
Installation
q Install in reverse order of removal.
[*1]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
q Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
q Air bleeding
2. Disconnect the swing motor and swing Refer to the “Bleeding air from various parts” in
machinery assembly (6), using forcing screw the Testing and adjusting chapter of this man-
[1] after removing the mounting bolts. [*1] ual.
Disassembly and assembly of 3. No. 1 sun gear

swing motor and swing Remove No. 1 sun gear (2).
machinery assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 796T-627-1630 Push tool q 1 Q

2 790-201-2350 Push tool t 1
3 790-201-2510 Push tool t 1
790-101-5531 • Plate 1
D 4 4. No. 1 carrier assembly
790-101-5421 • Grip 1
1) Remove No. 1 carrier assembly (3).
01010-51240 • Bolt 1
5 790-201-2870 Push tool t 1
6 790-201-2770 Push tool t 1
7 796T-626-1110 Push tool t 1 Q
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from
the swing machinery case.
6 Swing machinery case: Approx. 21 l
2. Swing motor assembly

1) Set the swing motor and swing machinery 2) Disassemble the No. 1 carrier assembly
assembly on block [1]. according to the following procedure.
2) Remove 10 mounting bolts and lift off Remove snap ring (4), and then remove
swing motor assembly (1). shaft (5), gear (6), bearing (7), thrust
washer (8), and plate (9).
4 Swing motor assembly: 115 kg
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 mounting bolt (12) of No. 2 carrier
assembly (13).
9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of
cover assembly (22).
2) Turn over case and pinion assembly (24) 10. Bearing

and set it on the press stand. Using push Using multiple push tools [3], remove bearing
tool [2], D1 and the press, pull out pinion (30) from case (31).
shaft assembly (25). a Push tool to be set contact with bearing:
a Set a wood block under the press so D2
that the pinion shaft will not be dam-
aged when it comes off.
a A rough standard pressing force is 20
odd tons.
Assembly
a Clean the all parts and check them for dirt or
3) Disassemble the pinion shaft assembly damage. Coat their sliding surfaces with
according to the following procedure. engine oil before installing.
i) Using the push tool, remove cover
assembly (22) and bearing (26) from 1. Bearing
shaft (27). Using push tool D3 and [4], press fit bearing
a A rough standard pressing force (26) to case (31).
is 30 tons. a A rough standard pressing force is several
ii) Remove oil seal (28) from cover (29). tons.
2. Cover assembly 3. Case assembly

1) Using push tool D4, press fit oil seal (28) 1) Turn over case assembly (32) and set it to
to cover (29). shaft (27). Using push tools D5, D6 and
2 Periphery of oil seal: [5], press fit the bearing inner race.
Gasket sealant (LG-6) a When setting the case assembly to
a Take care that the gasket sealant the shaft, take care extremely not to
(LG-6) will not stick to the oil seal lip damage the oil seal.
and shaft. a A rough standard pressing force is 30
tons.
2) Install cover assembly (22) to case (31)

and tighten mounting bolts (23). 2) Bearing
a Match the oil path of cover (22) to the Using too D7, press fit bearing (30).
drilled hole of case (31). a Press both inner race and outer race
2 Cover fitting face: of the bearing simultaneously. Do not
Gasket sealant (LG-6) press only the inner race.
3 Mounting bolt:
a A rough standard pressing force is 20
98 – 123 Nm {10 – 12.5 kgm} odd tons.
a After press fitting the bearing, check
2 Oil seal lip: Grease (G2-LI)
that the case turns smoothly.
4. No. 2 carrier assembly a When inserting the pin, do not set the
Assemble the No. 2 carrier assembly accord- 3 claws (a) on the periphery to the
ing to the following procedure. thin part of the carrier (b).
a There is a caulking mark made when The thin part may be on the opposite
the pin was inserted at the end of car- side, however. Check each carrier
rier side hole (a) and the inside wall of and avoid setting a claw to the thin
the hole is swelled at that mark. Flat- part.
1) Install plate (21) to carrier (16).
2) Install bearing (19) to gear (18) and fit top
and bottom thrust washers (17) and (20),
and then set the gear assembly to carrier
(16).
3) Aligning the pin holes of shaft (15) and
carrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve the
planetary gear and take care not to
damage the thrust washers.
4) Insert pin (14).
a After inserting the pin, caulk the pin

part of the carrier.
2) Install No. 2 carrier assembly (13).
5. Install No. 2 carrier assembly according to the

1) Set No. 2 carrier assembly to case.
2) Tighten bolt (12).
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
343 – 427 Nm {34 – 43.5 kgm}
3) Fit the O-ring to case.
6. No. 2 sun gear

Install No. 2 sun gear (11).
8. No. 1 carrier assembly

7. Ring gear according to the following procedure.
Using the eyebolt (M12 x 1.75), install ring i) Press fit shaft (5) to the carrier in the
gear (10). direction of the arrow until the snap
ring groove is seen.
ii) After installing snap ring (4), press
back the shaft from the opposite side
until the snap ring is fitted to face (P)
of the carrier. At this time, take care
not to press back too much.
a When installing ring gear (10), set its

match mark (d) and the projection of the
case flange (c) as shown in the following
figure.
a Degrease the mating faces of ring gear
(10) and case (29).
a Never stick gasket sealant to the mating iii) After installing plate (9), install thrust
faces of ring gear (10) and case (29). washer (8), bearing (7), gear (6), and
3 Mounting bolt:
snap ring (4).
245 – 309 Nm {25 – 31.5 kgm}
a Add engine oil (EO30-CD) at this time.
2) Install No. 1 carrier assembly (3). 10. Swing motor assembly

Install swing motor assembly (1) to ring gear
(10).
a When installing the swing motor assembly,
set the relief valve (f) and the projection of
the case (c) as shown in the following fig-
ure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear.
2 Mating faces of swing motor

assembly (1) and ring gear:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
9. No. 1 sun gear assembly 4 Swing motor assembly: 115 kg
Install No. 1 sun gear (2).

a Take care not to install the No. 1 sun gear Tighten the drain plug and add engine oil
upside down. (EO30-CD, or SHC 5W-30K for extremely cold
a Install the No. 1 sun gear with the tooth (e) district) through the oil filler to the specified
down. level.
5 Swing machinery case: Approx. 21 l
Removal and installation of swing Installation

circle assembly 1 q Carry out installation in the reverse order to
removal.
Removal [*1]
1. Remove the revolving frame assembly. For 2 Mating face of swing circle:
details, see “Removal and installation of Gasket sealant (LG-6)
2 Threads of swing circle mounting bolt:
revolving frame assembly”.
Adhesive (LT-2)
3 Swing circle mounting bolt:
2. Sling swing circle assembly (1) by 3 points
temporarily, remove 40 mounting bolts, and lift
824 – 1,030 Nm {84 – 105 kgm}
off the swing circle assembly. [*1]
Target: 927 Nm {94.5 kgm}
4 Swing circle assembly: 600 kg a When installing the swing circle to the
track frame, bring soft zone mark (S) of
the inner race and soft zone mark (P) of
the outer race to the right side of the chas-
sis as shown below.
2 Quantity of grease in grease bath:
Grease (G2-LI), 33 l
(Use GLT2-LI for 50°C specification)
UEN02656-00

© 2007 KOMATSU
All Rights Reserved
20
UEN02657-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Undercarriage and frame
Disassembly and assembly of carrier roller assembly .................................................................................... 2
Disassembly and assembly of track roller assembly ...................................................................................... 4
Disassembly and assembly of idler assembly ................................................................................................ 5
Disassembly and assembly of recoil spring assembly.................................................................................... 8
Removal and installation of sprocket ............................................................................................................ 10
Expansion and installation of track shoe assembly........................................................................................11
Removal and installation of revolving frame assembly ................................................................................. 13
Removal and installation of counterweight assembly ................................................................................... 16
Disassembly and assembly of q Floating seal

carrier roller assembly 1 a When installing the floating seal, thor-
oughly clean, degrease, and dry the con-
tact surfaces of the O-ring and floating
a Only precautions for assembling the carrier seal (hatched parts). Take care that dirt
roller assembly are explained below. will not stick to the floating seal contact
surfaces.
Special tools a Be sure to use the installer F1 to insert the
floating seal assembly in the housing.
Necessity
a After installing the floating seal, check that
Symbol
Sketch
Q’ty
N/R
Part number Part name its slant is less than 1 mm and its projec-
tion (a) is 5 – 7 mm.
1 791-430-3230 Installer t 1
F
2 791-601-1000 pump t 1
4 Carrier roller assembly: 30 kg
Assembly
q Press fitting of support (2)
1) Press fitting dimension of shaft: (Shown in
the following figure)
2) Using push tool [1], press fit support (2) to
shaft (1). At this time, apply press fitting
force of at least 21.6 – 24.5 kN {2.2 – 2.5
tons}. q Carrier roller
a Using tool F2, apply the standard pressure
to the oil filler to check the seal for air leak-
age.
a Keep the following standard pressure for
10 seconds and check that the pointer of
the gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
a Using tool F2, fill the carrier roller assem-

bly with oil and tighten the plug.
5 Carrier roller: 170 – 180 cc (EO30-CD)
Disassembly and assembly of q Track roller

track roller assembly 1 a Using tool G2, apply the standard pressure
to the oil filler to check the seal for air leak-
age.
a Only precautions for assembling the track a Keep the following standard pressure for
roller assembly are explained below. 10 seconds and check that the pointer of
the gauge does not lower.
Special tools Standard pressure: 0.1 MPa {1 kg/cm2}
Necessity
Symbol
Sketch
Q’ty
N/R
1 791-630-1780 Installer t 1
G
2 791-601-1000 Oil pump t 1
4 Track roller assembly: 75 kg (Single)

85 kg (Double)
Assembly
q Floating seal
a When installing the floating seal, thor- a Using tool G2, fill the track roller assembly
oughly clean, degrease, and dry the con- with oil and tighten the plug.
tact surfaces of the O-ring and floating
5 Track roller:
seal (hatched parts). Take care that dirt
280 – 310 cc (Single) (EO30-CD)
will not stick to the floating seal contact
280 – 290 cc (Double) (EO30-CD)
surfaces.
a Be sure to use the installer G1 to insert 3 Plug: 10 – 20 Nm {1 – 2 kgm}
the floating seal assembly in the housing.
its slant is less than 1 mm and its projec-
Disassembly and assembly of 4. Remove floating seal (7) on the opposite side
idler assembly 1 from idler (5) and shaft and support assembly
(6).
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 791-575-1520 Installer t 1
H
2 791-601-1000 Oil pump t 1
4 Idler assembly: 230 kg
Disassembly
5. Remove nut (8), pull out bolt (9), and then
remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
1. Remove nut (1) and pull out bolt (2) to remove

support (3).
2. Remove floating seal (4) from support (3) and

idler (5).
3. Pull out idler (5) from shaft and support assem-

bly (6).
a Idler is filled with oil of 345 ± 10 cc. Drain it
or spread cloths to soak it at this time.
Assembly a When installing the floating seal, thor-

1. Press fit bushings (12) (on both sides) to idler oughly clean, degrease, and dry the con-
(5). tact surfaces of the O-ring and floating
seal (hatched parts). Take care that dirt
2. Fit the O-ring and install support (10) to shaft will not stick to the floating seal contact
(11) with bolt (9) and tighten nut (8). surfaces.
a Be sure to use the installer H1 to insert the
floating seal assembly in the housing.
its slant is less than 1 mm and its projec-
a Install the shaft with the UP mark up.
4. Install shaft and support assembly (6) to idler

(5).
3. Using tool H1, install floating seal (7) to idler

(5) and shaft and support assembly (6).
5. Similarly, using too H1, install floating seal (4)

to idler (5) and support (3).
a Coat the sliding surface of the floating seal

with oil and take care that dirt will not stick
to it.
a Degrease the floating seal and the O-ring
contact surfaces.
6. Fit the O-ring, set support (3), install bolt (2),

and tighten nut (1).
7. Using tool H2, add oil and tighten the plug.

5 Quantity of oil:
Approx. 345 ± 10 cc (EO-30CD)
3 Plug: 130 – 180 Nm {13 – 18 kgm}
Disassembly and assembly of 1. Remove piston assembly (2) from recoil spring
recoil spring assembly 1 assembly (1).
2. Disassembly of recoil spring assembly

Special tools 1) Set tool J1 to recoil spring assembly (1).
k Since the installed load of the spring is
Necessity
large and dangerous, set the tool
Symbol
Sketch
Q’ty
N/R
Part number Part name securely.
a Installed load of spring:
791-685-8006 Compressor t 1 239.037 kN {24,375 kg}
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 t 1
(680 kN {70 t})
J 790-101-1102 Pump t 1
790-201-1500 Push tool kit 1
790-201-1660 • Plate 1
2
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4 Recoil spring (Excluding idler): 900 kg
Disassembly 2) Apply oil pressure gradually to compress

the spring and remove lock plate (3) and
nut (4).
a Compress the spring to a degree that
you can loosen the nut.
a Release the oil pressure gradually to
reduce the spring tension to 0 (zero).
a Free length of spring: 845.3 mm
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
3. Disassembly of piston assembly

1) Remove lock plate (11) from piston (10),
and then remove valve (12).
2) Remove snap ring (13), U-packing (14),
and ring (15).
Assembly 2) Install cylinder (7), collar (8), and yoke (6)

to spring (5), and then set them to tool J1.
2 Sliding parts of cylinder:
Grease (G2-LI)
3) Apply oil pressure gradually to compress

the spring and tighten nut (4) so that
installed length of the spring will be (a),
and then secure it with lock plate (3).
a Installed length of spring (a):
Approx. 690 mm
1. Assembly of piston assembly

1) Install ring (15) and U-packing (14) to pis-
ton (10) and secure them with snap ring
(13).
2) Tighten valve (12) temporarily and secure
it with lock plate (11).
2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylin-
der (7).
4) Remove recoil spring assembly (1) from
tool J1.
3. Install piston assembly (2) to recoil spring

assembly (1).
2 Sliding parts of piston: Grease (G2-LI)
2 Wear ring: Grease (G2-LI)
a Install the piston assembly so that the
position of the valve will be on outside.
a Supply 320 cc of grease (G2-LI) to the cyl-
inder, bleed air, and check that the grease
flows out of the grease hole.
Removal and installation of Installation

sprocket 1 q Install in reverse order of removal.
[*1]
Removal 2 Thread of sprocket mounting bolt:
1. Remove (26) track shoe assembly. For details, Gasket sealant (LG-6)
3
see “Removal and installation of track shoe Sprocket mounting bolt:
assembly”. 640 – 785 Nm {65 – 80 kgm}
2. Swing work equipment 90°, push up chassis

with work equipment and place block [1]
between track frame and track shoe.
3. Remove 26 mounting bolts and lift off sprocket

(1). [*1]
4 Sprocket: 70 kg
Expansion and installation of 4. Using tool K, remove master pin (1). [*3]
track shoe assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Remover and
1 791-650-3000 t 1
installer
K Cylinder
2 790-101-1300 t 1
(980 kN {100 t})
3 790-101-1102 Pump t 1
5. Move the master pin forward and set block [1]

Expansion of track shoe under the track shoe in front of the idler.
1. Start the engine and set the master pin to
above the idler. 6. Pull out pusher K.
2. Remove track shoes (2) on the right and left

sides of master pin (1). [*1]
3. Lower the work equipment to the ground and

loosen lubricator (3) to slacken the track shoe.
[*2]
k Since the internal pressure of the
adjustment cylinder is very high, do
not loosen the lubricator more than 1
turn. If the grease does not come out
sufficiently, move the machine forward
and in reverse.
7. Move the machine in reverse slowly to expand

the track shoe. [*4]
Installation of track shoe 2Apply grease to the contact faces of dust

q Carry out installation in the reverse order to seal (5) and bushing (4) (all over the
expansion. end face of the dust seal or bushing)
(parts marked O). Do not apply grease
[*1] to the pars marked (X), however.
2 Mounting bolt: Anti-seizure compound R: Detail of regular pin position
( M A R U Z E N M O LY M A X N o . 2 o r M: Detail of master pin position
equivalent) (Pins are not inserted, however)
3 Mounting bolt: Tighten the 4 bolts first to
392 ± 39 Nm {40 ± 4 kgm}. Check that
the mating faces are fitted, then
retighten each bolt by 120° ± 10°.
[*2]
a Adjust the tension of the track shoe. For
detail, see Testing and adjusting, “Check-
ing and adjusting track shoe tension”.
3 Tightening torque for lubricator:

58.8 – 88.3 Nm {6 – 9 kgm}
[*3]
a Using the tool, press fit the master pin so [*4]
that its projection (a) will be as follows. Set the track shoe and sprocket (4) as shown
q Dimension (a): 4.4 ± 2 mm in the following figure (on both right and left
sides).
2 Supply grease to the space between the

bushing and pin so that filling rate will
be 100%.
Grease: NIGTITE LYK-2 manufactured
by NIPPON GREASE CO., LTD. or
equivalent

revolving frame assembly 1
Removal
k Extend the arm and bucket fully, lower the
work equipment to the ground, and set the
work equipment lock lever to the LOCK
position.
1. Remove the work equipment assembly. For

details, see “Removal and installation of work
equipment assembly”.
2. Remove the counterweight assembly. For 6. Disconnect 7 hoses (5) – (11).

details, see “Removal and installation of coun- q (5): Centre swivel joint (Port D) – Swing
terweight assembly”. motor (Port T)
q (6): Centre swivel joint (Port D) – Hydrau-
3. Disconnect 4 boom cylinder hoses (1). lic tank
a Plug the hoses to stop oil. q (7): Centre swivel joint (Port E) – Sole-
noid valve
q (8): Centre swivel joint (Port B) – Control
valve left travel (Port B2)
q (9): Centre swivel joint (Port D) – Control
valve right travel (Port B5)
q (10): Centre swivel joint (Port A) – Control
valve left travel (Port A2)
q (11): Centre swivel joint (Port C) – Control
valve right travel (Port A5)
7. Pull out pin (12) on the centre swivel joint side

and disconnect the lock plate from the centre
swivel joint.
4. Sling boom cylinder assembly (2) temporarily.
5. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
a Remove the boom cylinder on the oppo-
site side similarly.
4 Boom cylinder assembly: 360 kg
8. Remove 29 mounting bolts (13), leaving 3 Installation

each at the front and rear sides. q Carry out installation in the reverse order to
removal.
[*1]
q Match the soft zone point (P) of the outer race
and the soft zone point (S) of the inner race.
2 Mating face of swing circle:
2 Threads of revolving frame mounting bolt:
Adhesive (LT-2)
9. Using a lever block, sling the revolving frame

assembly temporarily, balancing it in each
direction.
a Put wood liners to the rear side of the
frame.
q Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
a If the engine hood interferes with the sling,
erect the engine hood, referring to
“Removal and installation of radiator
assembly”.
10. Remove the remaining 6 bolts and lift off

revolving frame assembly (14). [*1]
k When removing the revolving frame
assembly, take care that it will not inter-
fere with the centre swivel joint assem-
bly.
4 Revolving frame assembly: 10,000 kg
3 Revolving frame mounting bolt

1. Tighten the bolts marked with A (at 4 places)
according to the following steps 1) – 3).
1) Tighten each bolt to 392 Nm {40 kgm} first.
2) Then, tighten the bolt by 90° ± 5°.
q Make a mark on the bolt head with a
marker pen (to check the angle).
3) The tightening torque of the bolt tightened
in 2) above must be 1,176 Nm {120 kgm}
or larger.
2. Tighten each bolt 208-25-71230 which is not

marked with A according to above steps 1) –
3). If the tightening torque reaches 2,254 Nm
{230 kgm} before completing the above steps
and the tightening angle is 35° – 95°, however,
stop tightening.
a Marks (P) and (S) are the soft zone points.

again.
q Bleeding air
Bleed air from the travel motor. For details, see
Testing and adjusting, “Bleeding air from vari-
ous parts”.
Removal and installation of 2. Open engine inspection cover at the counter-

counterweight assembly 1 weight side.
a Because the handle of the cover touches
the counterweight.
Removal
1. Remove the accessories on the counterweight 3. Set eyebolt [1] to counterweight assembly (2).
(Mirror specification) 4. Remove 4 mounting bolts (10). [*1]
1) Remove mirror (1).
2) Sling counterweight assembly (2).
5. Lift off counterweight assembly (2). [*2]

a Check where shims have been used.
(1-rear camera specification) a When lifting off the counterweight, take
1) Disconnect connector A40 (3) of camera 1 care not to strike it against the engine,
(RC1). radiator and cooler assembly, etc.
4
2) Disconnect connector CN-L09 (5) and wir-
Counterweight assembly: 9,500 kg
ing harness clamps (6) and (7) from rear
working lamp (4).
3) Sling counterweight assembly (2).
(2-rear camera specification)

1) Disconnect connector A40 (3) of camera 1
(RC1).
2) Disconnect connector CN-L09 (5) and wir-
ing harness clamps (6) and (7) from rear
working lamp (4). (If equipped)
3) Remove cover (8).
4) Disconnect coaxial cable connector (9) of
camera 2 (RC2).
Installation
removal.
a If heat insulation cover (11) of the engine
compartment is flattened, replace it.
[*1]
2 Threads of mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the exte-
rior parts (horizontal clearance) with
shims.
q Kinds of shim thickness: 0.5 mm, 1 mm
2) Insert the shims so that the clearance
between the door and counterweight and
that between the revolving frame and
counterweight will be 10 ± 5 mm evenly.
UEN02657-00

© 2007 KOMATSU
All Rights Reserved
18
UEN02658-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Hydraulic system
Removal and installation of centre swivel joint assembly ............................................................................... 2
Disassembly and assembly of centre swivel joint assembly ........................................................................... 4
Removal and installation of hydraulic tank assembly...................................................................................... 5
Removal and installation of control valve assembly ....................................................................................... 7
Disassembly and assembly of control valve assembly ................................................................................. 10
Removal and installation of hydraulic pump assembly ................................................................................. 14
Removal and installation of oil seal in hydraulic pump input shaft ................................................................ 17
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 18
Disassembly and assembly of travel PPC valve assembly........................................................................... 19
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 20
Removal and installation of centre q (15): Centre swivel joint (C port) – Right
swivel joint assembly 1 travel control valve (A5 port)
3. Pull out pin (16) on the side of centre swivel

Removal joint and remove the jam plate from the centre
k Release the remaining pressure in the swivel joint.
hydraulic circuit. For details, see Testing
and adjusting, “Releasing residual pres-
sure from hydraulic circuit”.
a Mark all the piping with tags to prevent mis-
takes in the mounting position when installing.
1. Disconnect six hoses (1) through (6) between

travel motor and centre swivel joint.
q (1): Centre swivel joint (T port) – Left
travel motor (T port)
q (2): Centre swivel joint (T port) – Right
travel motor (T port)
q (3): Centre swivel joint (B port) – Left
travel motor (PA port)
q (4): Centre swivel joint (D port) – Right 4. Remove four mounting bolts (17).
travel motor (PB port)
q (5): Centre swivel joint (A port) – Left
travel motor (PB port)
q (6): Centre swivel joint (C port) – Right
travel motor (PA port)
5. Remove centre swivel joint assembly (18). [*1]

4 Centre swivel joint assembly: 40 kg
2. Disconnect nine hoses (7) through (15).

q (7): Centre swivel joint (E port) – Left
travel motor (P port)
q (8): Centre swivel joint (E port) – Right
travel motor (P port)
q (9): Centre swivel joint (D port) – Swing
motor (T port)
q (10): Centre swivel joint (D port) – Hydrau-
lic tank
q (11): Centre swivel joint (E port) – Sole-
noid valve
q (12): Centre swivel joint (B port) – Left
travel control valve (B2 port)
q (13): Centre swivel joint (D port) – Right
travel control valve (B5 port)
q (14): Centre swivel joint (A port) – Left
travel control valve (A2 port)
Installation
q Install in reverse order of removal.
[*1]
Install the centre swivel joint facing in the direc-
tion shown in the diagram.
(The diagram shows the machine as seen from
above)
q Refilling with oil (hydraulic tank)

through the system. Then check the oil level
again.
q Bleeding air
Bleed the air from the travel motor. For details
see Testing and adjusting, “Bleeding air from
various parts”.
Disassembly and assembly of 1. Remove cover (1).

centre swivel joint assembly 1
2. Remove snap ring (2).
Special tools 3. Using tool M, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name 4. Remove seal (6) from swivel shaft (5).
790-101-2501 Push puller q 1 5. Remove O-ring (7) and slipper seal (8) from
790-101-2510 • Block 1 swivel rotor (4).
790-101-2520 • Screw 1
791-112-1180 • Nut 1
M 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
Disassembly
Assembly
1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer
to install.
2 Contact surface of rotor, shaft:
Grease (G0-LI or G2-LI)
a When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.
4. Install ring (3) and secure with snap ring (2).
5. Install O-ring and cover (1).

3 Mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
Removal and installation of 6. Disconnect block (7) together with return hose.
hydraulic tank assembly 1
Removal
1. Remove 3 lower covers (1).
7. Disconnect drain hoses (8), (9), and (10).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).

2. Drain the oil from the hydraulic tank.
6 Capacity of hydraulic tank:
Approx. 335 l
3. Remove control valve top cover (3).
10. Remove sensor (13).
11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily

and remove 6 mounting bolts (15). [*1]
5. Disconnect drain hoses (5) and (6).
13. Lift off hydraulic tank assembly (16). Installation

4 Hydraulic tank assembly: 200 kg q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
254.2 – 308.9 Nm {25.0 – 31.5 kgm}

again.
Approx. 335 l
Quantity of oil in tank (Centre of oil level
gauge): 248 l
q Bleeding air
various parts”.
Removal and installation of 5. Disconnect the 2 wiring connectors and 8

control valve assembly 1 hoses.
q (6): A51 (Front pump pressure sensor)
q (7): A52 (Rear pump pressure sensor)
Removal q (8): Port PS hose (Hose band: Yellow-Blue)
k Lower the work equipment to the ground q (9): Port PST hose (Hose band: Brown)
and stop the engine. Then, loosen the q (10): Port PPS2 hose (Rear pump, red)
hydraulic oil filler cap slowly to release the q (11): Port PR hose (Solenoid)
internal pressure of the hydraulic tank and q (12): Port PR hose (Pump, yellow)
set the work equipment lock lever to the q (13): Port PP1 hose (Front pump)
LOCK position. q (14): Port PP2 hose (Rear pump)
a Put tags to the disconnected hoses and tubes q (15): Port T hose (Oil cooler)
to prevent a mistake in re-connecting them.
1. Open engine inspection cover (1).
2. Remove control valve top cover (2).
6. Disconnect the following 4 control valve hoses:

q (16): Port PPS1 hose (Front pump)
q (17): Port PLS2 hose (Hose band: Brown)
q (18): Port PLS1 hose
q (19): Port PX1 hose (Hose band: Blue)
3. Remove partition covers (3), (4), and (5)
between the engine and control valve. 7. Remove relay bracket (20) and clamp (21).
8. Disconnect drain hose (22). (To tank)
9. Disconnect the following 6 left PPC hoses.

q (23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm OUT (Hose band: Yellow)
4. Remove the control valve bottom cover.
10. Disconnect 4 boom hoses (24). 15. Disconnect the following 6 right PPC hoses.
q (30): Bucket DUMP (Hose band: Black)
11. Remove boom tube clamps (25) and (26). q (31): Left travel FORWARD
(Hose band: Red)
q (32): Boom LOWER (Hose band: Brown)
q (33): Right SWING
q (34): Right travel FORWARD
(Hose band: Green)
q (35): Arm IN (Hose band: Blue)
12. Disconnect port TSW hose (27) (Swing motor

port S).
13. (28): In order from top

Remove port A-1 tube (Boom Hi bottom side).
Remove port A1 tube (Bucket bottom side).
Disconnect port A2 hose (Swivel joint port A). 16. Disconnect the following 3 control valve hoses.
After removing the hoses from ports B, remove a Do not disconnect hose C.
port A3 tube (Boom bottom side). q (36): Port BP5 hose (To solenoid)
Remove port A4 hose (Swing motor port MB). q (37): Port PX2 hose
Disconnect port A5 hose (Swivel joint port C). q (38): Port TS hose
Remove port A6 tube (Arm head side).
14. (29): In order from top

Disconnect port B-1 hose (Arm Hi bottom side).
Disconnect port B1 hose (Bucket head side).
Disconnect port B2 hose (Swivel joint port B).
Remove port B3 tube (Boom head side).
Remove port B4 hose (Swing motor port MA).
Disconnect port B5 hose (Swivel joint port D).
Remove port B6 tube (Arm bottom side).
17. Sling control valve assembly (40) temporarily Installation

and remove 3 mounting bolts (39). q Carry out installation in the reverse order to
removal.

again.
q Bleeding air
various parts”.
18. Lift off control valve assembly (40).

4 Control valve assembly: 250 kg
Disassembly and assembly of Replacement procedure for pressure compen-

control valve assembly 1 sation valve seal
a Since there many types of the pressure com-
pensation valves, make a mark on each valve
a Only precautions for assembling the pressure
to indicate from where it was removed.
compensation valve assembly and control
valve assembly are explained below.
1. Remove piston (2), plug (3), and spring (4)
from pressure compensation valve (1).
Special tools
2. Remove seal (5) and O-ring (6) from piston (2).
Necessity
Symbol
Sketch
Q’ty
N/R
796-946-1310 Guide Ø21.8

1
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide Ø20.9
1 1
(For 723-46-44100)
796-946-2210 Guide Ø20.6
1
(For 723-46-45100, 723-46-45500)
796-946-1320 Guide
1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide Ø21.6
1
(For 723-46-42800) a There many types of the pistons.
2
796-946-2120 Guide a Clean the pressure compensation valve
L 1 thoroughly. Then, using the tool, install
(For 723-46-44100)
seals as shown in the figure.
796-946-2220 Guide
1
(For 723-46-45100, 723-46-45500) 3. Fit O-ring (6) to piston (2).
796-946-1330 Sleeve
1 4. Set tool L1 to piston (2) and push it in with your
(For 723-46-40100, 723-46-40601)
hand slowly so that seal (5) will expand evenly.
796-946-1430 Sleeve
1 a You may push in the seal to the flat part of
(For 723-46-42800) the tool first, and then install the tool to the
3
796-946-2130 Sleeve piston and push in the seal further.
1
(For 723-46-44100)
796-946-2230 Sleeve
1
(For 723-46-45100, 723-46-45500)
5. Set tool L2 to piston (1) for other seal (3) and Assembly
push it in with your hand slowly so that seal (3) q Apply engine oil to the sliding surfaces of the
will expand evenly. parts before installing.
a You may push in the seal to the flat part of q When installing spools (7) and (10) in the valve
the tool first, and then install the tool to the chamber, direct drilled holes (8) and (11)
piston and push in the seal further. toward cylinder ports (9) and (12).
6. Install correcting tool L3 to piston (1) for about

1 minute to fit seals (2) and (3).
a Check that the seal are not projected or
broken.
q Install filters (13) to the bottom of ports PLS1

and PLS2 as shown below.
7. Fit plug (3) and spring (4) to piston (2) and

assemble pressure compensation valve (1).
a If these parts are difficult to install, do not
push them in forcibly, but install them to
correcting tool L3 to fit the seals, and then
install them to the piston.
a After assembling, push the piston with
your hand and check that it is returned by
only the spring force.
3 Mounting bolt of back pressure valve,

boom Hi check valve, quick return
valve, lock valve, and arm plate:
58.8 – 73.6 Nm {6 – 7.5 kgm}
q Control valve top and bottom covers

2 Mating faces of control valve top and
bottom covers:
SEALEND 242 or equivalent
a Use 2 washers (W2) each for only 2
places of the control valve top cover.
q Tighten the mounting bolts of the control valve
top and bottom covers in the following order.
(A o D o C o B)
3 Mounting bolt of control valve top and
bottom covers:
156.9 – 176.5 Nm {16 – 18 kgm}
q Merge-divider valve
2 Mating face of merge-divider valve:
SEALEND 242 or equivalent
q Tighten the mounting bolts of the merge-
divider valve similarly to those of the control
valve covers.
3 Mounting bolt of merge-divider valve:

156.9 – 176.5 Nm {16 – 18 kgm}
q Tighten the mounting bolts of the boom Hi

check valve, quick return valve, lock valve, and
arm plate similarly to those of the control valve
covers.
q Pressure compensation valve

a When installing each pressure compensa-
tion valve, check the mark made when it
was removed.
q Main relief valve assembly

After installing the main relief valve to the con-
trol valve, see Testing and adjusting, “Measur-
ing and adjusting oil pressure in work
equipment, swing, and travel circuits”.
Removal and installation of 2. Remove the hydraulic tank strainer. Using tool
hydraulic pump assembly 1 C, stop the oil.
a When not using tool C, remove the drain
plug to drain the oil from the hydraulic tank
Special tools and piping.
6 Hydraulic tank: Approx. 335 l
Necessity
Symbol
Sketch
Q’ty
N/R
796-460-1210 Oil stopper q 1

C
796-770-1320 Adapter q 1
Removal
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
k Disconnect the cable from the negative (–)
terminal of the battery.
a Put tags to the disconnected hoses and tubes
to prevent a mistake in re-connecting them. 3. Drain the oil from the flywheel housing.
1. Remove 2 lower covers (1). 4. Open the main pump side cover.
5. Open the engine hood.
6. Lift off covers (2) and (3) together.
8. Remove stay (5).
9. Disconnect the following 2 pump wiring con- 11. Sling hydraulic pump assembly (18) temporar-
nectors. ily and remove 12 mounting bolts (17).
q (6): V22 (PC-EPC solenoid valve)
Band colour: Red
q (7): V21 (LS-EPC solenoid valve)
Band colour: White
10. Disconnect the following 10 hoses and 1 tube.

q (8): EPC basic pressure port hose
(Band colour: Yellow)
q (9): Rear pump pressure input port hose
(Band colour: Red)
q (10): Rear pump discharge port hose
q (11): Front pump discharge port hose
q (12): Drain port hose
q (13): Front load pressure input port hose
q (14): Rear load pressure input port hose 12. Lift off hydraulic pump assembly (18). [*1]
(Band colour: Red)
q (15):Front pump pressure input port hose 4 Hydraulic pump assembly: 260 kg
q (16): Pump suction port tube
Installation
removal.
[*1]
2 Hydraulic pump involute spline:
Anti-friction compound (LM-G)
2 Mating face of hydraulic pump case:

3 Flywheel housing drain plug:
42.1 – 70.6 Nm {4.3 – 7.2 kgm}
level.

again.
Approx. 335 l
Quantity of oil in tank (Centre of oil level
gauge): 248 l
q Bleeding air
various parts”.
Removal and installation of oil Installation

seal in hydraulic pump input q Install in reverse order of removal.
shaft 1
[*1]
2 Oil seal lip portion: Grease (G2-LI)
Removal 2 Oil seal outer circumference: Grease (G2-LI)
1. Remove the hydraulic pump assembly. Refer a Coat the oil seal outer circumference
to the “Removal of hydraulic pump assembly” thinly with grease.
section. a Press-fit oil seal (3), using tool [1].
2. Remove snap ring (1) and then remove spacer

(2).
3. Pry off oil seal (3) with a screwdriver. [*1]

a When attempting to pry off the seal, do not
damage the shaft.
Disassembly and assembly of a When installing pistons (8), apply grease

work equipment PPC valve to their outside and the inside of the valve
body holes.
assembly 1 3 Mounting bolt of plate (5):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a Only precautions for assembling the work 2 Sliding parts of joint (4):
equipment PPC valve assembly are explained 2 – 4 cc of Grease (G2-LI)
2 Female threads of body (A):
below.
Adhesive (LT-2)
a Apply a drop (about 0.02 g) of LOCTITE to

each of the 2 threaded parts of the body
as shown in the figure, and then tighten
joint (4).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
a Observe the tightening torque of the joint.
2 Contact parts of piston and disc (2):

Grease 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 69 – 88 Nm {7 – 9 kgm}
Assembly a When installing disc (2), adjust the play to
q Work equipment PPC valve assembly 0.5 – 3 mm at 200 mm from the turning
a Install springs (11 ) with the small-diame- centre of the lever.
ter (inside diameter) end on the shim (12)
side.
a Springs (10 ) having different number of
turns are used for the following hydraulic
ports. Take care when installing them.
Installed height: 31.9 mm (Common to all
springs)
Installed load:
P1, P2: 35.3 N {3.6 kg}
P3, P4: 21.6 N {2.2 kg}
a The position of each port is stamped on

the underside of valve body.
2 Piston (8): Grease (G2-LI)
Disassembly and assembly of

travel PPC valve assembly 1
Disassembly
a Only precautions for assembling the travel
PPC valve assembly are explained below.
Assembly
q Travel PPC valve assembly
a Insert shim (3) of the thickness and quan-
tity checked when disassembled.
Standard shim thickness: 0.3 mm
a Since spring (4) is not symmetric verti-
cally, install it with the small-diameter
(inside diameter) end on the shim side.
2 Periphery of piston (7) and inside of
hole of body (1): Grease (G2-LI)
2 Sliding part of shaft (13) (4 – 8 cc),
contact parts of lever (12) and 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). Do
not drive in pin (18), bushing (19) by hit-
ting it directly with a hammer.
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Piston rod assembly
1) Remove the piping from the cylinder
assembly.
Special tools 2) Remove the mounting bolts and discon-
nect cylinder head assembly (1).
Necessity
Symbol
Sketch
3) Pull out piston rod assembly (2).
Q’ty
N/R
a Put a container under the cylinder to
receive oil.
Cylinder repair
1 790-502-1003 t 1
stand
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring (For boom
796-720-1680 q 1
and bucket)
Clamp (For boom
4 07281-01589 q 1
and bucket)
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
• Push tool 4) Disassemble the piston rod assembly
790-201-1851 1
(For bucket)
N • Push tool i) Set piston rod assembly (2) to tool N1.
790-201-1861 1
5 (For boom)
• Push tool
790-201-1871 1
(For arm)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Plate
6 790-201-1660 (For bucket)
1
• Plate
790-201-1670 1
(For boom)
• Plate
790-201-1680 1 ii) Remove piston assembly lock screw (3).
(For arm)
a This work is common to the boom,
arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75
a If screw (3) is so caulked that you

cannot remove it, tighten it temporar-
ily and tap the threads on it, and then
remove it.
vii) Remove cap (8), 11 balls (9), and

plunger (10).
q Perform this work for only the
arm cylinder.
iii)Using tool N2, remove piston assem- a Since cap (8) is made of nylon,
bly (4). tighten a screw into it and pull it
q When not using tool N2, loosen with pliers.
the piston assembly by using the
drilled holes (Ø10: 2 places) (in
which the pins of N2 are inserted
in the following figure).
iv) Remove plunger (5).
boom and arm cylinder.
v) Remove collar (6).
boom and arm cylinder.
vi) Remove head assembly (7).
2. Disassembly of piston assembly Assembly

1) Remove rings (11). a Take care not to damage the packings, dust
2) Remove wear rings (12). seals, O-rings, etc.
3) Remove piston ring (13). a Clean the all parts. After installing them, cover
4) Remove the O-ring and backup rings (14). the piping ports and pin holes to prevent dirt
from entering.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60°C and then insert it.
3. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18). 1. Assembly of cylinder head assembly
4) Remove buffer ring (19). 1) Using tool N5, press fit bushing (20).
5) Remove snap ring (21). 2) Install buffer ring (19).
6) Remove bushing (20). 3) Install rod packing (18).
4) Using tool N6, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).
6) Install snap ring (21).
2. Assembly of piston assembly 3. Piston rod assembly

1) Using tool N3, expand piston ring (13). 1) Set the piston rod to tool N1. (Refer to the
a Set piston ring (13) to tool N3 and procedure 1 - 4) of disassembly.)
turn the handle 8 – 10 times to 2) Install cylinder head assembly (7) to the
expand the piston ring. piston rod.
2) Set tool N4 and contract piston ring (13). 3) Fit the O-ring and backup ring to collar (6),
and then install them.
q Perform this work for only the boom
and arm cylinders.
4) Install plunger (5).
q Perform this work for only the boom
and arm cylinders.
3) Install backup ring and O-ring (14).

4) Install wear ring (12).
5) Install ring (11).
a Do not increase the closed gap of the
ring too much.
2 Ring groove: Grease (G2-LI) 5) Set plunger (10) to the piston rod. Install
11 balls (9) and secure them with cap (8).
a After installing the plunger, check that
it has a little play at its end.
q Perform this work for only the arm cyl-
inder.
6) Assemble piston assembly (4) according iii) Make a screw hole to install screw
to the following procedure. (3).
q When reusing the rod and piston a Apply a drill to the V-groove of
assembly (4) the threaded parts of piston (4)
i) Tighten piston assembly (4). Then, and rod (2) and make a hole.
using tool N2, tighten piston assem- a When making a hole on the cylin-
bly (4) until the screw holes are der (arm cylinder) having the bot-
aligned. tom cushion, make it around the
a Remove the burrs from the cushion plug.
threads with a file. q Dimensions of screw hole (mm)
Go to iv).
Tap drill diameter Tap to be used
10.3 12 x 1.75
Tap drill Tapping

hole depth depth
Bucket/
27 20
Boom
Arm 36 29
iv) Tighten screw (3).

a Clean the parts thoroughly and
remove metal chips, dirt, etc.
2
q When replacing either or both of Threads of screw:
the rod and piston assembly (4) Adhesive (LOCTITE No. 262)
3 Screw:
with new ones
a Make a mark of the cushion plug
58.9 – 73.6 Nm {6 – 7.5 kgm}
position on the end of the rod having
the bottom cushion. v) Caulk the threaded part [1] by 4 places
q Perform this work for only the arm cyl- with a punch.
inder.
ii) Using the tool, tighten piston assem-
bly (4) until it reaches the end of the
rod.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, check
that plunger (5) has some play.
boom and arm cylinders.
7) Install piston rod assembly (2).

a Set the abutment joint of the ring at a
side and insert the piston rod, aligning
it with the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.
8) Tighten the mounting bolts of cylinder

head assembly (7).
3 Mounting bolt:
Cylinder
Tightening torque
name
Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm}
Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54.0 ± 8 kgm}
9) Install the piping.
UEN02658-00

© 2007 KOMATSU
All Rights Reserved
26
UEN02659-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
Removal and installation of work 4. Start the engine and retract the piston rod.
equipment assembly 1 a Bind the rod with wires, etc. so that it will
not be extracted and lower it onto a stand
or put a wood block to the bottom side so
Special tools that the cylinder will not lower. When
putting the wood block, remove the grease
Necessity
fitting on the bottom side.
Symbol
Sketch
Q’ty
N/R
Part number Part name a Disconnect the boom cylinder on the
opposite side similarly.
796-670-1100 Remover q 1 a When slinging the boom cylinder, if the
796-670-1110 • Sleeve 1 sling interferes with the work equipment
lamp, remove the work equipment lamp.
796-670-1120 • Plate 1
796-670-1130 • Screw 1 5. Disconnect intermediate connector A42 (6) for
796-870-1110 • Adapter 1 the work equipment lamp.
P 01643-33080 • Washer 1
6. Disconnect 3 arm cylinder hoses (7) and 2
01803-13034 • Nut 1
bucket cylinder hoses (8).
790-101-4000
Puller
q 1 a Put oil stopper plugs and secure the
(490 kN {50t}, long) hoses to the valve side with ropes.
Pump
790-101-1102 q 1
(294 kN {30t})
Removal
k Extend the arm and bucket fully, lower the
work equipment to the ground, and set the
work equipment lock lever to the LOCK
position.
k See Testing and adjusting, “Releasing resid-
ual pressure from hydraulic circuit”.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2) temporarily

7. Sling work equipment assembly (12) temporar-
and remove lock bolt and nut (3). [*1]
ily.
3. Remove plate (4) and head pin (5). [*2]
8. Remove cover (9), plate (10), and foot pin (11)
a Check the quantity and positions of the
to disconnect work equipment assembly (12).
inserted shims.
[*3]
q When removing with tool P Installation

Remove plate (10). Sling and set tool P q Carry out installation in the reverse order to
and remove foot pin (11) to disconnect removal.
work equipment assembly (12).
a Check the quantity and positions of the [*1]
inserted shims. a Tighten the locknut so that clearance (a)
between the plate and nut will be 0.5 – 1.5 mm.
9. Move the machine in reverse to remove work

equipment assembly (12). [*2]
2
4 Work equipment assembly: Inside wall of bushing before assembling pin:
PC400-8, PC400LC-8: 7,400 kg Anti-friction composition (LM-P)
PC450-8, PC450LC-8: 8,400 kg 2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance (b)
between cylinder rod (12) and plate (4) will be
1.5 mm or less.
Standard shim: 1.0, 2.0 mm
[*3]
2 Inside wall of bushing before assembling pin:
Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance (c)
between boom (13) and bracket (14) will be 1
mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
q Bleeding air
various parts”.

again.
UEN02659-00

© 2007 KOMATSU
All Rights Reserved
6
UEN02660-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Cab and its attachments
Removal and installation of operator cab assembly ....................................................................................... 2
Removal and installation of operator cab glass (stuck glass) ......................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
Removal and installation of floor frame assembly ........................................................................................ 22
Removal and installation of 9. Remove rear covers (10) to (13).

operator cab assembly
Removal
k Disconnect the negative terminal (–) of the
battery before starting the work.
1. Remove front window (1).

2. Remove step plate (2).
3. Remove floor mat (3).
4. Refer to “Removal and installation of monitor

assembly”, and remove monitor assembly (4).
5. Remove covers (5) and (6). 10. Remove duct (14).

6. Remove cover duct assembly (7). 11. Remove cover (15).
a Disconnect connector H15 fixed on the
back from the clip.
7. Insert key (8), turn it right, and open the out-

side-air filter cover.
8. Remove outside-air filter (9).

14. Remove lock pin (18) and remove duct (19).
15. Remove duct (20). 23. Remove ducts (32) and (33).
16. Disconnect connector L03 (21). a Cut tie-wrap.
17. Remove plates (22) and (23) from the operator 24. Disconnect wiper motor connector M05(34).
cab. 25. Remove harness (35) and antenna (36) from
the cab wall.
a Cut 2 points of tie-wrap.
18. Disconnect connectors K01(25) and CK02

(26).
19. Pass over and disconnect antenna (24) from 26. Remove duct (37).
KOMTRAX communication modem (K). 27. Remove duct (38) upper and lower.
20. Disconnect connector M10(27) from the opera-
tor's cab. (If equipped)
21. Disconnect cab wiring intermediate connectors

H09(28), H08(29), and H16(30).
a Cut tie-wrap (T),
22. Disconnect radio antenna (31).
a (23) is removed plate.
28. Disconnect window washer hose (39).

29. Disconnect harness clamp (40).
30. Haul in antenna (36).
31. Detach harness clamp (41) from the right back 35. Lift off and remove operator cab assembly
side of operator cab. (47).
4 Operator cab assembly: 470 kg
32. Remove bolt (42) under the operator cab and

remove lock plate (43). [*1]
33. Remove bolt (44). [*2]
Installation
q Installation is done in the reverse order of
removal.
[*1]
3 Mounting bolt of lock plate (43):
98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Bolt (44):
245 – 309 Nm {25 – 31.5 kgm}
34. Dismount 6 mounting bolts (45) and 4 mount-

ing nuts (46).
a Check the bolt length beforehand.
Removal and installation of operator cab glass (stuck glass)
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator cab, 5 panes (1) to (4) and (2) : Left side rear window glass
(18) are stuck. (3) : Door lower window glass
a In this section, the procedure for replacing the (4) : Front window glass
stuck glasses is explained. (5) : Front window assembly
a When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to (6) : Dam rubber
replace only the front window glass while the (17) : Centre trim seal
front window assembly is installed to the opera- (18) : Rear glass
tor cab.)
a For the procedure for replacing the front win-
dow assembly, see “Removal and installation of
front window assembly”.
Special tools (The figure shows the operator cab of a wheel

loader.)
Necessity
Symbol
Sketch
Q’ty
N/R
2 793-498-1210 Lifter (Suction cup) t 2
X
3 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator cab
(metal sheet)(8).
a If the window glass is broken finely, it may

be removed with a knife [4] and a screw-
driver.
a Widening the cut with a flat blade screw-
driver, cut the dam rubber and adhesive
with knife [4].
(The figure shows the operator cab of a wheel

loader.)
a If a seal cutter is not available, make holes

on the adhesive and dam rubber with a
drill and pass a fine wire (piano wire, etc.)
[2] through the holes. Then, grip the both
ends of the wire with priors [3], etc. (or
hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and dam rubber.
Since the wire may be broken by the fric-
tional heat, apply lubricant to the wire.
2. Remove the window glass.
Installation a Even if the primer is packed again just

1. Using a knife and scraper [5], remove the after it is unpacked, use it within 24 hours
remaining adhesive and dam rubber from the after it is unpacked for the first time.
metal sheets (glass sticking surfaces) of the (Discard the primer 24 hours after it is
operator's cab. unpacked.)
a Remove the adhesive and dam rubber to 1) Stir the primers for both of paint and glass
a degree that they will not affect adhesion sufficiently before using them.
of the new adhesive. Take care not to a If the primer has been stored in a refrig-
scratch the painted surfaces. erator, leave it at the room temperature
(If the painted surfaces are scratched, for at least half a day before stirring it.
adhesion will be lowered.) (If the primer is unpacked just after
taken out of the refrigerator, water will
(The figure shows the operator cab of a wheel be condensed. Accordingly, leave the
loader.) primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
2. Remove oil, dust, and dirt, etc. form the stick-

ing surfaces of operator cab (8) and window
glass (9) with white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave 3) Evenly apply the paint primer to the surfaces
them for at lease 5 minutes to dry. to stick dam rubber and its outside surfaces
(The figure shows the operator's cab of a wheel to apply adhesive on operator cab (8).
2 Paint primer:
loader.)
Sunstar primer for painting plane
580 super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
3. Apply primer (10).

a The using limit of primer is 4 months after
the date of manufacture. Do not use the
primer after this limit.
a Use the primer within 2 hours after un-
packing it.
a Parts to be coated with primer; Apply the prim- a Never apply the wrong primer.
er all over dimension (a). If the glass primer, etc. is applied by mistake,
q Dimension to apply primer (a): 25 mm wipe it off with white gasoline.
4) Apply the glass primer to the sticking sur-

faces of window glass (9).
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
a In addition to the above parts, additionally

apply the primer to right side window glass (1)
and door lower window glass (3).
q Range to apply primer additionally for right side
window glass (1): (b)
q Range to apply primer additionally for door
lower window glass (3): (c)
a After applying the primer, leave it for at least 5

minutes (within 8 hours) to dry.
a Parts to be coated with primer; Apply
the primer to all around of sticking
surface (d) of window glass (9) for
dam rubber (6) installation position
and operator cab (8).
a Do not apply the primer to the
boarder about 5mm wide between the
black part and transparent part of the
glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a Never apply the wrong primer.
If the paint primer, etc. is applied by
mistake, wipe it off with white gaso-
line.
4. Stick dam rubber (both-sided adhesive a Stick dam rubber (6a) additionally to
tape)(6) along the inside edge of the glass right side window glass (1).
sticking section. q Positions to stick additional dam rub-
a Do not remove the release tape of dam ber to the right side window glass:
rubber on the glass sticking side before (f): 50 mm
sticking the glass. (g): 90 mm
a When sticking the dam rubber, do not (h): 250 mm
touch the cleaned surface to the utmost.
a Care should be taken not to float the dam
rubber of each sticking corner.
2) Stick dam rubber (6) for left side window

glass (2) to the position as shown in the
figure.
a When sticking dam rubber (6) around a
frame, do not lap its finishing end over the
starting end. Or, make clearance of about
5 mm between them (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
3) Stick dam rubber (6) for door lower win- a Stick dam rubber (6c) of the lower
dow glass (3) to the position as shown in side of the front window glass along
the figure. the outside edge of the lower line, dif-
ferently from other dam rubbers (6).
(If it is stuck along the inside, it will be
seen through the transparent part of
the glass.)
a Stick dam rubber (6b) additionally to

door lower window glass (3).
q Positions to stick additional dam
rubber to the door lower window
class: 5. Position the new window glass.
(j) : 110 mm 1) Check the clearance between the window
(k) : 90 mm glass and the operator cab on the right,
(m) : 200 mm left, upper, and lower sides, and then posi-
tion the window glass to be the clearances
evenly.
2) Stick tapes [6] between window glass (9)
and operator cab (8) and draw positioning
line (n).
a Stick tapes [6] for positioning to 3
points, that is, right, left and lower
parts of the right side window glass,
left side rear window glass, and door
lower window glass for accurate posi-
tioning.
3) Cut the tape between window glass (9)
and operator cab (8) with a knife, etc. and
then remove the window glass.
4) Stick dam rubber (6) for front window a Do not remove the tapes left on the
glass (4) to the position as shown in the window glass and the operator cab
figure. before installing the window glass.
a When positioning front window glass

2) Cut the tip of the adhesive nozzle (14) so
(4), set its horizontal position to the
that dimensions (q) and (r) will be as fol-
frame width.
lows.
And set its vertical position to make
the height difference (p) between the q Dimension (q): 10 mm
frame top and the front window glass q Dimension (r): 15 mm
3 mm.
3) Set adhesive cartridge (12) to caulking

6. Apply adhesive. gun [7].
a Use either of two types of adhesives a An electric caulking gun is more effi-
according to the season. cient.
2 Adhesive (Apr. to Oct.):
Sunstar penguine seal 580 super “S”
or equivalent
2 Adhesive (Oct. to Apr.):
Sunstar penguine seal 580 super “W”
or equivalent
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the
all hardened part form the nozzle tip.
1) Break aluminium seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
4) Remove the release tape of dam rubber

on the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator cab.
a Apply adhesive (15) with dimensions

(s) and (t) for dam rubber (6) of oper-
ator cab (8).
q Dimension (s): 10 mm
q Dimension (t): 15 mm
a Apply adhesive (15) higher than dam
rubber (6).
a Apply the adhesive evenly with same
height level.
7. Install the window glass.

1) Install window class (9), matching it to the
lines of the positioning tapes drawn in step
5.
a Since the window glass cannot be
removed and stuck again, stick it with
utmost caution.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking window glass (9), press all
around of it until it sticks to the dam rubber
closely.
a Apply adhesive (15) additionally to
a Press the corners of the window glass
additional dam rubber (6a) of right
firmly.
side window glass and additional dam
rubber (6b) of door lower window
glass.
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X2.
a After installing front window glass (4),

fill the clearances between it and cen-
tre trim seal (16) with caulking mate-
rial in range (s) with dimensions (t)
and (u).
After applying the primer to glass (4)
of section A-A, apply the adhesive as
caulking material.
q Caulking dimension (t): 2 mm
q Caulking dimension (u): 5 mm
a When caulking, mask the glass side
and form the adhesive with a rubber
spatula as shown in the figure.
a Wipe off the projected adhesive.
2 Glass primer:
Sunstar primer for glass 580
super or equivalent
2 Adhesive:
SUNSTAR penguine seal 580
super “S” or “W” or equivalent
8. Fix the window glass. 9. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator cab and window glass.
X3 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
a When cleaning the glass, do not give an
impact on it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours.
(at temperature of 20°C and humidity of
60%)
2) After removing the stopper rubbers, sty-
rene foam blokes, and rubber bands, wait
at least 14 hours, that is, at least 24 hours
in total, before operating the machine
actually.
2) By using styrene foam blocks [9] and rub-

ber bands [10], fix the window glass and
the dam rubber to fit them completely.
Removal and installation of front

window assembly
k Lower the work equipment completely to
the ground and stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the oper-
ator's cab. The procedure for removing and
installing the front window assembly (front
frame and front window glass) is explained
below.
Removal
1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
2. Remove left corner block (1) and right corner

block (2). [*1]
a Mounting bolt (4) and washer (3) for left

corner block are used to hang the pull-up
assist cable in the following step 6.
6. Remove left lower pin (7). [*2]

a By removing left lower pin (7), plate (8) at
the end of pull-up assist cable (9) comes
off.
a Hang plate (8) on the mounting bolt of left
corner block (use washer) and set in
place.
k The return load of 58.8 N {6 kg} is
applied to the rear of the operator cab.
3. Release the rear lock of the operator cab. Accordingly, take care when removing
left lower pin (7) to disconnect pull-up
4. Lower the front window assembly carefully a assist cable (9).
little. Put out rollers (5) and (6) under the both
sides of the front window through the portion
from which the corner blocks were removed in
the above step 2. (the portion where the rail is
open) and hold them.
5. Remove rollers (5) and (6) under the both

sides of the front window.
9. Twist front window assembly (10) to the right

and left to remove both upper rollers (11) and
(12) from the rails, and then remove front win-
dow assembly (10).
7. Pull out the bottom of front window assembly

(10) though the rail opening portion and lower
it gradually.
8. Lower front window assembly (10) completely.

a Do not let the front window assembly
touch the monitor.
Installation a Install the right corner block so that clear-

q Carry out installation in the reverse order to ance (a) between the rail and right corner
removal. block (2) becomes 0 – 2.0 mm.
a Install the right corner block so that there
[*1] is no level difference at the rolling surface
q Adjust opening and closing of the front window (R) of the roller.
assembly according to the following proce-
dure.
1. Open and close the front window to check that
it does not interfere with the rails and that the
rollers are not hitched.
2. If there is any problem in opening and closing
of the front window, loosen the mounting bolt of
roller adjustment bracket (13) and adjust the
condition of the front window, and then tighten
the mounting bolt again.
a Make sure that bracket (13) is not
mounted on the angle.
3 Mounting bolt: 34.3 Nm {3.5 kgm}
5. Install left corner block (1).

a Fully tighten the block after adjusting the
“Close” position in the following step 6.
a Install the left corner block so that clear-
ance (b) between the rail and left corner
block (1) becomes 0 – 2.0 mm.
a Install the left corner block so that there is
no level difference at the rolling surface
(R) of the roller. (Refer to the above fig-
ure.)
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are securely fastened.
4. Install right corner block (2).

a Fully tighten the block after adjusting the
“Close” position in the following step 6.
6. Adjust the “Close” position of the front window

assembly lock according to the following pro-
cedure.
1) Tighten left and right corner blocks (1) and
(2) at roughly right positions so that front
window glass (14) is attached firmly to
cab-side trim seal (15).
7. After the adjustment, splash water heavily over

the front window glass and check that the
water does not leak into the operator cab.
2) Check the working condition of right and

left locks (16) and (17) when opening and
closing the front window assembly.
q If right and left locks (16) and (17) do
not work normally.
1] Loosen lock fitting bolt (18), move
lock (16) forward, and then tighten the
bolt again.
a The same applies to the right
side.
2] After moving the lock, re check the fit-
ness of front window glass (14) and
cab-side trim seal (15) which was
checked in step 1).
3] Repeat the work in 1] and 2] until the
fitness of the front window glass and
the working condition of locks (16)
and (17) are both acceptable, and
then tighten the mounting bolts of the
right and left corner blocks.
8. Adjust the “Open” position of the front window 3) Close front window assembly (10).
assembly lock. 4) Loosen locknut (20) of right and left side of
1) After adjusting the “Close” position of the rubber stoppers (18), and then pull back
front window assembly lock in steps 6 and both rubber stoppers (18) so that they
7, raise the front window assembly to the won't contact with the front window
ceiling. assembly when it is in “Open” position.
2) Set the front window assembly locks at
the both sides of rear of the operator cab
to the “Open” position, and then check the
following items.
q Check the working condition of right
and left locks (1 6) an d (17) (as
explained above).
q Front window assembly must be in
contact with the right and left rubber
stoppers (18) and furthermore, must
be pushing them backward for 1.5 –
3.0 mm.
q The front window assembly must be
pushing the limit switch backward for
4 – 7 mm. 5) Loosen both sides of locknuts (22), and
a The position of limit switch (19) can- adjust the position of striker bolt (21).
not be adjusted. Therefore, the a Striker bolt (21): M10
“Open” position of the front window Inner diameter of plate (23): ø 14.5
assembly is decided within the range mm
where this switch works.
a Limit switch (19) is used to prevent
the windshield wiper from moving
when turning the wiper switch on by
m i s ta k e w h e n t h e f r o n t w i n d o w
assembly is in “Open” position. If the
wiper operates when there is no glass
in the front, the wiper falls down
inside the cab and causes trouble.
To check whether limit switch (19) is
working, turn the key switch on and
see that, even if the wiper switch is
turned on, the wiper does not operate
when the front window assembly is in
“Open” position.
1] Front window assembly (10) must be
pushing the limit switch backward for
4 – 7 mm (at “Open” position).
2] Working condition of lock (17).
q After checking the above items, if it

becomes necessary to do the adjust-
ment.
6) Adjustment of right and left rubber stop- 4] Tighten locknuts (20) of the both
pers (18). sides of rubber stopper (18).
1] Bring front window assembly (10) (the
lock should be in “Open” position) into
contact with right and left rubber stop-
pers (18).
9. Adjust stopper (24) of the front window assem-

bly.
1) Adjust and lock both sides of stopper (24)
2] Close front window assembly (10). so that when pulling up the front window
3] Turn right and left rubber stoppers assembly, surface (d) of stopper (D) of
(18) to the left for one and a half front window assembly (10) is in contact
rotation. with surface (c) of stopper (24).
a One turn of rubber stopper (18)
to the left is equivalent to
squashing the rubber for approxi-
mately 1.5 mm.
a When the front window assembly
is in “Open” position, the front
window assembly must be push-
ing right and left rubber stoppers
(18) for 1.5 – 3.0 mm.
10. Check the operating effort of the lock of the

front window assembly.
1) After finishing the adjustment of steps 6 –
9, check that latching efforts of both right
and left locks (16) and (17) are even.
a Check the latching efforts on both
“Close” side (in the front of the opera-
tor cab) and “Open” side (in the rear
of the operator's cab).
[*2]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
Removal and installation of floor 5. Disconnect ground (2).

frame assembly
Removal
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a). 6. Disconnect the following PPC hoses from the
a Never release the refrigerant (R134a) to the travel PPC valve. The colour of the band is;
atmosphere. q (3): Red
q (4): No colour
k If refrigerant gas (R134a) gets in your eyes, q (5): Green
you may lose your sight. Accordingly, put q (6): Blue
on protective goggles while you are collect- a Prepare an oil sump.
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant 7. Disconnect top and bottom of connector (7).
(R134a). Collecting and filling work must be Top: P09
conducted by a qualified person. Bottom: P10
1. Turn the upper structure by 90°.
2. Drain the engine coolant.

3. Remove the operator's cab assembly by refer-

ring to “Removal and installation of operator's
cab assembly”.
q Step 8 – 10 is optional (for breaker). 20. Remove clamps (24) and (25). [*2]
8. Disconnect the following PPC hoses from the 21. Disconnect clamp (26). (If equipped)
PPC valve. The colour of the band is;
q (8): Yellow
q (9): No colour
a Plug the hose to stop oil flow-out.
9. Disconnect connectors S11 (10) and S10 (11).
10. Disconnect connectors P13 (12) and V30 (13).
22. Disconnect connectors N10 (27) and AC01

(28).
23. Disconnect connectors ECU10 and ECU11
( 2 9 ) f r o m t h e a ir c o n d i t i o n e r c o n t r o l l e r
(ACCONT).
24. Cut tie-wrap (30) and draw in wiring harness
11. Disconnect ground (14). From the left, (31).
T04, T05, T06, T07, T09, T10 25. Disconnect the clamp of wiring harness (32).
12. Disconnect clamp (15).
13. Disconnect connector A08 (16) from the clip.
14. Disconnect connector P17 (17) from the air
conditioner tube.
15. Remove the clamp and disconnect spacer
(18).
16. Disconnect hose (19).
a Check the connecting point.
a Disconnect the work equipment PPC hose
(P) at joint box side. (See item 33.)
26. Disconnect connector H15 (33).

27. Remove grommet (34).
28. Move wiring harness (35) to the outside of the
floor frame.
a (SP) is made of sponge.
17. Disconnect hose (20).

18. Disconnect heater hose (21).
19. Remove mounting bolt (22) and disconnect air
conditioner tube (23). [*1]
29. Disconnect the clamp of wiring harness (35).

30. Move plates (36) and (37) together with wiring
harness (35) to the boom side.
34. Pull out PPC hose assembly (41) of the work

equipment.
31. Open the engine hood and remove cover (38).
35. Sling floor frame assembly (42) and remove it.

a Make sure that the hoses, connectors,
32. Disconnect clamp (39). clamps, and so on are disconnected with-
33. Disconnect PPC hose (40) of the work equip- out fail.
4 Floor frame assembly: 250 kg
ment. From the top, the colour of the band is:
White
Brown
None
Blue
Black
Green
Red
Yellow
a Prepare an oil sump.
Installation
removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexcel:
ZXL100PG (PAG 46 or equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
a Make sure that the hoses do not lap over.
q Filling air conditioner circuit with refriger-

ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
UEN02660-00

© 2007 KOMATSU
All Rights Reserved
26
UEN02661-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and installation of KOMTRAX communication modem assembly.................................................... 5
Removal and installation of monitor assembly................................................................................................ 6
Removal and installation of pump controller assembly ................................................................................... 8
Removal and installation of engine controller ............................................................................................... 10
Removal and installation of air 7. Pull down opening and closing lever (8) of the
conditioner unit assembly outside air filter cover.
8. Remove outside air filter (9).
Removal
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose
when the coolant temperature in the radia-
tor is high, you may be scalded. In this
case, wait until the coolant temperature
lowers and then disconnect the heater
hose.
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the 9. Remove rear covers (10) to (13).
atmosphere.
k If refrigerant gas (R134a) gets in your

eyes, you may lose your sight. Accord-
ingly, put on protective goggles while you
are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the
refrigerant (R134a). Collecting and filling
work must be conducted by a qualified
person.
1. Turn the upper structure by 90°.
2. Drain the engine coolant.

3. Remove front window (1).

4. Remove step plate (2).
5. Remove floor mat (3).
10. Remove duct (14).

a Disconnect connector H15 fixed on the
back from the clip.
16. Remove ducts (22) and (23).

a Cut tie-wrap.
17. Remove duct (24) upper and lower.
18. Remove duct (25) upper and lower.
13. Remove plate (17). 19. Disconnect plate (26) from the cab wall.
14. Remove lock pin (18) and remove duct (19).
15. Remove ducts (20) and (21). 20. Disconnect connectors N10 (27) and AC01
a Cut tie-wrap. (28).
21. Disconnect connectors ECU10 and ECU11
( 2 9 ) f r o m t h e a ir c o n d i t i o n e r c o n t r o l l e r
(ACCONT).
22. Loosen tie-wrap (30) and draw in wiring har-

ness (31).
23. Remove cover (32). Installation

removal.
[*1]
a When installing the air conditioner circuit hoses,
take care so that dirt, water, may not enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration on
the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (Denso: ND-OIL8, Zexcel:
24. Remove mounting bolt (33) and disconnect air ZXL100PG (PAG 46 or equivalent)).
conditioner tube (34). [*1] 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
25. Disconnect heater hose (35).

a Check the connecting point. q Filling air conditioner circuit with refriger-
ant (R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 870 ± 50 g
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
26. Remove the 7 mounting bolts and air condi-

tioner unit assembly (36).
Removal and installation of KOM-

TRAX communication modem
assembly
Removal
1. Remove covers (1) – (4).
2. Twist antenna wire (5) and disconnect it.

3. Disconnect connectors K01(6) and CK02 (7).
4. Remove the 4 mounting bolts and KOMTRAX
communication modem assembly (8).
Installation
removal.

monitor assembly
Removal
1. Remove cap (1).

2. Remove cover (2) and then disconnect wiring
connector P31 (3) for air conditioner sunlight
sensor (S).
3. Remove duct (4).
4. Remove cover (5) as follows. [*1]
1) Insert flat-head screwdriver inside slit (SL)
and push it upward. 5. Remove the 4 mounting bolts and lift monitor
2) Release lock (L) and remove the cover. assembly (6). [*2]
3) Disconnect wiring connector M04 of the 6. Disconnect connectors CM01 (7), CM02 (8)
cigarette lighter from the back of cover (5). and CM03 (9).
a Since CM02 (8) and CM03 (9) can be
installed reversely, be careful not to mis-
take. CM 03 (9) is a green connector.
7. In the case of rear camera specification, dis-
connect connector CN-5 (11).
8. Disconnect connector (10).
Installation
[*1], [*2]
1) Temporarily install monitor assembly (6) with 4
mounting bolts, and then install cover (5).
2) With cover (5) installed, tighten the mounting
bolts of monitor assembly.
q Carry out the rest of installation in the reverse

order to removal.
Removal and installation of pump

controller assembly
Removal
Installation
q Installation is done in the reverse order of re-
moval.
a Reference
1. Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2. Disconnect relay R08 (4) from the clip.
2) Move lever (3) up.
3. Disconnect bracket (5) and put it to the right
side.
4. Disconnect wiring connectors C01 (6) and C02
(7) as follows.
q Tilt lock (L12) inside while pressing lock
(L1).
a Bar (B) comes out and the lock is re-
leased.
5. Remove the 4 mounting bolts and pump con-
troller assembly (8).
3) Lightly push part (A) of connector cover

(1) from both sides to unfasten claw (B).
4) Remove connector cover (1) around claw
(C).
a Connector without connector cover 3) Set claw (C) to the connector and place
(1) connector cover (1).
a Take care that wiring harness (5) will
not be caught.
2. Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
possible. 4) Set claw (B) and install connector cover
(1).
a Right and left sliders (4) pushed in as

far as possible (Left figure) 5) Bind connector cover (1) and wiring har-
2) Move lever (3) of connector cover (1) from ness with a new cable tie. (See 1. 1).)
the upper position to the left position (lock
position) in the figure.
a (B), (C): Claws
a If the sliders and lever are not set as
shown in the following figure, the con-
nector is not disconnected or locked
securely with the lever. Accordingly,
check their positions again.

engine controller
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open the engine hood.
2. Disconnect connectors EC01 (1), ENG (2), and

CE03 (3).
3. Remove engine controller (4).
Installation
removal.
UEN02661-00

© 2007 KOMATSU
All Rights Reserved
12
UEN02244-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic circuit diagram................................................................................................................................. 3
UEN02244-00 90 Diagrams and drawings
Hydraulic circuit diagram
Hydraulic circuit diagram PC450, PC450LC, PC450LCD, PC450LCHD-8 1 PC450,PC450LC,PC450LCD,PC450LCHD-8
UEN02244
PC450, 450LC, 450LCD, 450LCHD-8 3
Hydraulic circuit diagram
Hydraulic circuit diagram PC450, PC450LC, PC450LCD, PC450LCHD-8 1 PC450,PC450LC,PC450LCD,PC450LCHD-8
UEN02244
PC450, 450LC, 450LCD, 450LCHD-8 5
90 Diagrams and drawings UEN02244-00
UEN02244-00

© 2007 KOMATSU
All Rights Reserved
8
UEN02245-00
PC450-8
PC450LC-8
PC450LCD-8
PC450LCHD-8

PC450-8 K50001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
UEN02245-00 90 Diagrams and drawings
Electrical circuit diagram PC450, PC450LC, PC450LCD, PC450LCHD-8 1
Electrical circuit diagram (1/5)
UEN02245-00 3
UEN02245-00 5
UEN02245-00 7
UEN02245-00 9
UEN02245-00 11
90 Diagrams and drawings UEN02245-00
13
UEN02245-00

© 2007 KOMATSU
All Rights Reserved
14

PC 400 - 450 LC-8

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UEN02223-00

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs UEN02223-00

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Troubleshooting of engine (S-mode) UEN02653-00

50 Disassembly and assembly

90 Diagrams and drawings

Foreword and general information UEN02226-00

10 Structure, function and maintenance standard

Hydraulic system, Part 3 UEN02235-00

20 Standard value table

30 Testing and adjusting

Adjusting play of work equipment and swing PPC valves........................................................... 46

Failure code [CA273] PCV2 Short Error ..................................................................................... 54

Failure code [DXA0KB] PC-EPC Sol. S/C................................................................................... 38

H-12 Work equipment has big time lag ....................................................................................... 18

50 Disassembly and assembly

Disassembly and assembly of final drive assembly .................................................................... 3

90 Diagrams and drawings

PC450/LC/LCD/LCHD-8 Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

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

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips