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Komatsu PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Hydraulic Excavator Service Manual

1,029 pages · Publication SEN03578-04

$109.83
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Models
PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0
Serial coverage
PC400-7E0 60001-60089, 65001 and up, PC400LC-7E0 60001-60089, 65001 and up, PC450-7E0 30001-30058, 65001 and up, PC450LC-7E0 30001-30058, 65001 and up
Manual type
Service Manual
Pages
1,029
Publication
SEN03578-04
Condition
Brand new
Komatsu PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Hydraulic Excavator Service Manual, publication SEN03578-04

What's inside

From the manual's own table of contents: 8 sections, 377 entries. See sample pages (PDF, 882 KB)

Index and foreword47 topics
  • Shop Manual, contents binder, binder label and tabs
  • Index and foreword
  • Foreword and general information
  • Specification
  • Specification and technical data
  • Structure, function and maintenance standard
  • Engine and cooling system
  • Power train
  • Undercarriage and frame
  • Hydraulic system, Part 1
  • Hydraulic system, Part 2
  • Hydraulic system, Part 3
  • Work equipment
  • Cab and its attachments
  • Electrical system
  • Standard value table
  • Standard service value table
  • Testing and adjusting
  • Testing and adjusting, Part 1
  • Testing and adjusting, Part 2
  • Testing and adjusting, Part 3
  • Troubleshooting
  • Failure code table and fuse locations
  • Information related to troubleshooting
  • Troubleshooting by failure code (Display of code), Part 1
  • Troubleshooting by failure code (Display of code), Part 2
  • Troubleshooting by failure code (Display of code), Part 3
  • Troubleshooting of electrical system (E-mode)
  • Troubleshooting of hydraulic and mechanical system (H-mode)
  • Troubleshooting of engine (S-mode)
  • Disassembly and assembly
  • General information on disassembly and assembly
  • Hydraulic system
  • Diagrams and drawings
  • Hydraulic diagrams and drawings
  • Electrical diagrams and drawings
  • Composition of shop manual
  • Safety notice
  • How to read the shop manual
  • Explanation of terms for maintenance standard
  • Handling of electric equipment and hydraulic component
  • Handling of connectors newly used for engines
  • How to read electric wire code
  • Precautions when carrying out operation
  • Method of disassembling and connecting push-pull type coupler
  • Standard tightening torque table
  • Conversion table
Specification4 topics
  • Specification dimension drawings
  • Specifications
  • Weight table
  • Table of fuel, coolant and lubricants
Structure, function and maintenance standard36 topics
  • Engine related parts
  • Radiator, oil cooler and aftercooler
  • Final drive
  • Sprocket
  • Swing machinery
  • Swing circle
  • Track frame and recoil spring
  • Idler
  • Carrier roller
  • Track roller
  • Track shoe
  • Hydraulic equipment layout drawing
  • Hydraulic tank and filter
  • Hydraulic pump
  • Control valve
  • CLSS
  • Functions and operation by valve
  • Merge-divider valve
  • Attachment circuit selector valve
  • Holding valve
  • Valve control
  • PPC valve
  • Solenoid valve
  • PPC accumulator
  • Return oil filter
  • Center swivel joint
  • Travel motor
  • Swing motor
  • Hydraulic cylinder
  • Dimensions of components
  • Air conditioner piping
  • Engine control
  • Electronic control system
  • Monitor system
  • Sensor
  • KOMTRAX system
Standard value table3 topics
  • Standard value table for engine related parts
  • Standard value table for chassis related parts (Backhoe specification)
  • Standard value table for chassis related parts (Loading shovel specification)
Testing and adjusting41 topics
  • Tools for testing, adjusting and troubleshooting
  • Measuring engine speed
  • Measuring air boost pressure
  • Measuring exhaust temperature
  • Measuring exhaust gas color
  • Adjusting valve clearance
  • Measuring compression pressure
  • Measuring blow-by pressure
  • Measuring engine oil pressure
  • Measuring EGR valve and bypass valve drive pressure
  • Handling fuel system parts
  • Releasing residual pressure from fuel system
  • Measuring fuel pressure
  • Handling during cylinder cut-out operation
  • Handling during no injection cranking operation
  • Measuring fuel return rate and leakage
  • Bleeding air from fuel circuit
  • Checking fuel circuit for leakage
  • Checking and adjusting fan belt and alternator belt tension
  • Checking and adjusting air conditioner compressor belt tension
  • Measuring swing circle bearing clearance
  • Checking and adjusting track shoe tension
  • Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
  • Measuring control circuit basic pressure
  • Checking and adjusting pump PC control circuit oil pressure
  • Checking and adjusting pump LS control circuit oil pressure
  • Measuring solenoid valve output pressure
  • Measuring PPC valve output pressure
  • Adjusting play of work equipment and swing PPC valves
  • Inspecting locations of hydraulic drift of work equipment
  • Releasing residual pressure from hydraulic circuit
  • Measuring oil leakage amount
  • Bleeding air from various parts
  • Special functions of machine monitor
  • Procedure for turning on KOMTRAX terminal
  • Indication by KOMTRAX terminal lamps
  • Handling voltage circuit of engine controller
  • Preparation work for troubleshooting of electrical system
  • Procedure for testing diodes
  • Pm clinic service
  • Undercarriage troubleshooting report
Troubleshooting190 topics
  • Failure codes table
  • Before carrying out troubleshooting when failure code is displayed
  • Points to remember when troubleshooting
  • Sequence of events in troubleshooting
  • Checks before troubleshooting
  • Classification and troubleshooting steps
  • Information in troubleshooting table
  • Connection table for connector pin numbers
  • T- branch box and T- branch adapter table
  • Failure code [AA10NX] Aircleaner Clogging
  • Failure code [AB00KE] Charge Voltage Low
  • Failure code [B@BAZG] Eng Oil Press. Low
  • Failure code [B@BAZK] Eng. Oil Level Low
  • Failure code [B@BCNS] Eng. Water Overheat
  • Failure code [B@BCZK] Eng. Water Lvl Low
  • Failure code [B@HANS] Hydr. Oil Overheat
  • Failure code [CA111] ECM Critical Internal Failure
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg Air Press Sensor High Error
  • Failure code [CA123] Chg Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
  • Failure code [CA132] Throttle Sensor Low Error
  • Failure code [CA135] Eng Oil Press Sensor High Error
  • Failure code [CA141] Eng Oil Press Sensor Low Error
  • Failure code [CA144] Coolant Temp Sens High Error
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg Air Temp Sensor High Error
  • Failure code [CA154] Chg Air Temp Sensor Low Error
  • Failure code [CA187] Sens Supply 2 Volt Low Error
  • Failure code [CA221] Ambient Press Sens High Error
  • Failure code [CA222] Ambient Press Sens Low Error
  • Failure code [CA227] Sens Supply 2 Volt High Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA238] Ne Speed Sens Supply Volt Error
  • Failure code [CA263] Fuel Temp Sensor High Error
  • Failure code [CA265] Fuel Temp Sensor Low Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA273] PCV2 Short Error
  • Failure code [CA274] PCV2 Open Error
  • Failure code [CA322] Inj #1 (L/B#1) Open/Short Error
  • Failure code [CA323] Inj #5 (L/B#5) Open/Short Error
  • Failure code [CA324] Inj #3 (L/B#3) Open/Short Error
  • Failure code [CA325] Inj #6 (L/B#6) Open/Short Error
  • Failure code [CA331] Inj #2 (L/B#2) Open/Short Error
  • Failure code [CA332] Inj #4 (L/B#4) Open/Short Error
  • Failure code [CA342] Calibration Code Incompatibility
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sens Supply 1 Volt Low Error
  • Failure code [CA386] Sens Supply 1 Volt High Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA554] Rail Press Sensor In Range Error
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA757] All Persistent Data Lost Error
  • Failure code [CA778] Eng Bkup Speed Sensor Error
  • Failure code [CA1228] EGR Valve Servo Error 1
  • Failure code [CA1625] EGR Valve Servo Error 2
  • Failure code [CA1633] KOMNET Datalink Timeout Error
  • Failure code [CA2185] Throt Sens Sup Volt High Error
  • Failure code [CA2186] Throt Sens Sup Volt Low Error
  • Failure code [CA2249] Rail Press Very Low Error
  • Failure code [CA2271] EGR Valve Lift Sens High Error
  • Failure code [CA2272] EGR Valve Lift Sens Low Error
  • Failure code [CA2351] EGR Valve Sol Current High Error
  • Failure code [CA2352] EGR Valve Sol Current Low Error
  • Failure code [CA2555] Grid Htr Relay Volt Low Error
  • Failure code [CA2556] Grid Htr Relay Volt High Error
  • Failure code [D110KB] Battery Relay Drive Short Circuit
  • Failure code [D196KA] Service Return Relay Open Circuit
  • Failure code [D196KB] Service Return Relay Short Circuit
  • Failure code [DA25KP] 5V Sensor 1 Power Abnormality
  • Failure code [DA80MA] Auto. Lub. Abnormal
  • Failure code [DA2RMC] Pump Comm. Abnormality
  • Failure code [DA2SKQ] Model Selection Abnormality
  • Failure code [DAFRMC] Monitor Comm. Abnormality
  • Failure code [DGH2KB] Hydr Oil Sensor Short Circuit
  • Failure code [DHPAMA] F Pump Press Sensor Abnormality
  • Failure code [DHPBMA] R Pump Press Sensor Abnormality
  • Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
  • Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
  • Failure code [DW43KA] Travel Speed Sol. Open Circuit
  • Failure code [DW43KB] Travel Speed Sol. Short Circuit
  • Failure code [DW45KA] Swing Brake Sol. Open Circuit
  • Failure code [DW45KB] Swing Brake Sol. Short Circuit
  • Failure code [DW91KA] Travel Junction Sol. Open Circuit
  • Failure code [DW91KB] Travel Junction Sol. Short Circuit
  • Failure code [DWJ0KA] Merge-divider Sol. Open Circuit
  • Failure code [DWJ0KB] Merge-Divider Sol. Short Circuit
  • Failure code [DWK0KA] 2-stage Relief Sol. Open Circuit
  • Failure code [DWK0KB] 2-stage Relief Sol. Short Circuit
  • Failure code [DXA0KA] PC-EPC Sol. Open Circuit
  • Failure code [DXA0KB] PC-EPC Sol. Short Circuit
  • Failure code [DXE0KA] LS-EPC Sol. Open Circuit
  • Failure code [DXE0KB] LS-EPC Sol. Short Circuit
  • Failure code [DXE4KA] Service Current EPC Open Circuit
  • Failure code [DXE4KB] Service Current EPC Short Circuit
  • Failure code [DY20KA] Wiper Working Abnormality
  • Failure code [DY20MA] Wiper Parking Abnormality
  • Failure code [DY2CKB] Washer Drive Short Circuit
  • Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
  • Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
  • Before carrying out troubleshooting of electrical system
  • Information contained in troubleshooting table
  • E-1 Engine does not start
  • E-2 Auto-decelerator does not operate
  • E-3 Automatic warming-up does not operate
  • E-4 Preheater does not operate
  • E-5 All work equipment, swing, and travel mechanism do not move
  • E-6 Power maximizing function does not operate
  • E-7 Machine monitor does not display at all
  • E-8 Machine monitor does not display some items
  • E-9 Contents of display by machine monitor are different from applicable machine
  • E-10 Fuel level monitor was lighted in red while engine running
  • E-11 Engine coolant temperature gauge does not indicate normally
  • E-12 Hydraulic oil temperature gauge does not indicate normally
  • E-13 Fuel level gauge does not operate normally
  • E-14 Swing lock monitor does not indicate normally
  • E-15 When monitor switch is operated, monitor displays nothing
  • E-16 Windshield wiper does not operate
  • E-17 Machine push-up function does not operate normally
  • E-18 Monitoring function fails to display “boom RAISE” normally
  • E-19 Monitoring function fails to display “boom LOWER” normally
  • E-20 Monitoring function fails to display “arm IN” normally
  • E-21 Monitoring function fails to display “arm OUT” normally
  • E-22 Monitoring function fails to display “bucket CURL” normally
  • E-23 Monitoring function fails to display “bucket DUMP” normally
  • E-24 Monitoring function fails to display “swing” normally
  • E-25 Monitoring function fails to display “travel” normally
  • E-26 Monitoring function fails to display “travel differential pressure” normally
  • E-27 Monitoring function fails to display “service” normally
  • E-28 The KOMTRAX system does not operate normally
  • E-29 Air conditioner does not operate
  • E-30 Travel alarm does not sound or does not stop sounding
  • E-31 Horn does not sound
  • System chart for hydraulic and mechanical system
  • H-1 All work equipment lack power, or travel and swing speeds are slow
  • H-2 Engine speed sharply drops or engine stalls
  • H-3 No work equipment, swing or travel move
  • H-4 Abnormal noise is heard from around hydraulic pump
  • H-5 Auto-decelerator does not work
  • H-6 Fine control mode does not function or responds slow
  • H-7 Boom moves slowly or lacks power
  • H-8 Arm moves slowly or lacks power
  • H-9 Bucket moves slowly or lacks power
  • H-10 Work equipment does not move in its single operation
  • H-11 Work equipment has a bit too fast hydraulic drift
  • H-12 Work equipment has big time lag
  • H-13 Other work equipment moves when relieving single circuit
  • H-14 Power max. switch does not operate
  • H-15 Machine push-up function does not operate
  • H-16 In compound operation of work equipment, speed of part loaded more is low
  • H-17 When machine swings and raises boom simultaneously, boom rising speed is low
  • H-18 When machine swings and travels simultaneously, travel speed lowers largely
  • H-19 Machine deviates during travel
  • H-20 Travel speed is low
  • H-21 Machine is not steered well or steering power is low
  • H-22 Travel speed does not change or travel speed is low or high
  • H-23 Travel system does not move (only one side)
  • H-24 Upper structure does not swing
  • H-25 Swing acceleration or swing speed is low
  • H-26 Upper structure overruns remarkably when it stops swinging
  • H-27 Large shock is made when upper structure stops swinging
  • H-28 Large sound is made when upper structure stops swinging
  • H-29 Hydraulic drift of swing is large
  • H-30 Attachment circuit is not changed
  • H-31 Oil flow in attachment circuit cannot be controlled
  • Method of using troubleshooting chart
  • S-1 Starting performance is poor
  • S-2 Engine does not start
  • S-3 Engine does not pick up smoothly
  • S-4 Engine stops during operations
  • S-5 Engine does not rotate smoothly
  • S-6 Engine lacks output (or lacks power)
  • S-7 Exhaust smoke is black (incomplete combustion)
  • S-8 Oil consumption is excessive (or exhaust smoke is blue)
  • S-9 Oil becomes contaminated quickly
  • S-10 Fuel consumption is excessive
  • S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
  • S-12 Oil pressure drops
  • S-13 Oil level rises (Entry of coolant or fuel)
  • S-14 Coolant temperature becomes too high (overheating)
  • S-15 Abnormal noise is made
  • S-16 Vibration is excessive
Disassembly and assembly45 topics
  • How to read this manual
  • Coating materials list
  • Special tools list
  • Sketches of special tools
  • Removal and installation of fuel supply pump assembly
  • Removal and installation of fuel injector assembly
  • Removal and installation of engine front seal
  • Removal and installation of engine rear seal
  • Removal and installation of cylinder head assembly
  • Removal and installation of radiator assembly
  • Removal and installation of hydraulic oil cooler assembly
  • Removal and installation of aftercooler assembly
  • Removal and installation of engine and hydraulic oil pump assembly
  • Removal and installation of travel motor and final drive assembly
  • Disassembly and assembly of final drive assembly
  • Removal and installation of swing motor and swing machinery assembly
  • Disassembly and assembly of swing machinery assembly
  • Removal and installation of swing circle assembly
  • Disassembly and assembly of carrier roller assembly
  • Disassembly and assembly of track roller assembly
  • Removal and installation of idler, recoil spring assembly
  • Disassembly and assembly of idler assembly
  • Disassembly and assembly of recoil spring assembly
  • Removal and installation of sprocket
  • Expansion and installation of track shoe assembly
  • Removal and installation of revolving frame assembly
  • Removal and installation of counterweight assembly
  • Removal and installation of center swivel joint assembly
  • Disassembly and assembly of center swivel joint assembly
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of control valve assembly
  • Disassembly and assembly of control valve assembly
  • Removal and installation of hydraulic pump assembly
  • Removal and installation of oil seal in hydraulic pump input shaft
  • Disassembly and assembly of work equipment PPC valve assembly
  • Disassembly and assembly of travel PPC valve assembly
  • Disassembly and assembly of hydraulic cylinder assembly
  • Removal and installation of work equipment assembly
  • Removal and installation of operator’s cab
  • Removal and installation of operator’s cab glass (stuck glass)
  • Removal and installation of front window assembly
  • Removal and installation of air conditioner unit assembly
  • Removal and Installation of KOMTRAX terminal assembly
  • Removal and installation of monitor assembly
  • Removal and installation of pump controller
Diagrams and drawings3 topics
  • Hydraulic circuit diagram
  • Electrical circuit diagram
  • Connector list and stereogram

Inside this manual

Real pages from this service manual (1,029 pages). Open the sample pages (PDF, 881 KB)

Sample pages from the Komatsu PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0 Hydraulic Excavator Service Manual: Specifications, Troubleshooting, Diagram, Color page, Foldout diagram
  • Specifications, page 404: 30 Testing and adjusting
  • Troubleshooting, page 554: Failure code [CA131] Throttle Sensor High Error
  • Diagram, page 644: Failure code [CA2351] EGR Valve Sol Current High Error
  • Color page, page 468: 30 Testing and adjusting
  • Foldout diagram, page 1,022: Electrical circuit diagram (1/5)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN03578-04$109.83
Other manuals for the PC400-7E0, PC450-7E0, PC450LC-7E0

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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,029 pages

Quantity one is the manual described above.

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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu Galeo PC400LC-7E0Service Manual · CEBM016902 · $89.81

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