Komatsu PC400-8, PC400LC-8, PC450-8, PC450LC-8 Hydraulic Excavator Service Manual
1,079 pages · Publication SEN02223-15
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What's inside
From the manual's own table of contents: 190 sections, 348 entries. See sample pages (PDF, 791 KB)
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
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine related parts
Radiator, oil cooler and aftercooler
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Track frame and recoil spring
Idler
Show all 190 sections
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 valve48 topics
- PPC accumulator
- Anti-drop valve for boom
- Anti-drop valve for arm
- Return oil filter
- Center swivel joint
- Travel motor
- Swing motor
- Hydraulic cylinder
- Work equipment
- Dimensions of components
- Air conditioner piping
- Engine control
- Electronic control system
- Monitor system
- Sensor
- KOMTRAX system
- Standard value table for engine related parts
- Standard value table for chassis related parts
- Standard value table for chassis related parts (Loading shovel specification)
- Tools for testing, adjusting and troubleshooting
- Sketches of special tools
- Testing engine speed
- Testing air boost pressure
- Testing exhaust temperature
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Testing EGR valve drive pressure
- Handing fuel system parts
- Releasing residual pressure from fuel system
- Testing fuel pressure
- Handing during cylinder cut-out operation
- Handing during no injection cranking operation
- Testing fuel return and leakage
- Bleeding air from fuel circuit
- Checking fuel circuit for leakage
- Checking and adjusting fan belt and alternator belt
- Checking and adjusting air conditioner compressor belt tension
- Testing swing circle bearing clearance
- Checking and adjusting track shoe tension
- Testing and adjustment oil pressure in work equipment, swing, and travel circuits
- Testing control circuit basic pressure
- Checking and adjusting pump PC control circuit oil pressure
- Checking and adjusting pump LS control circuit oil pressure
- Testing solenoid valve output pressure
- Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Inspecting locations of hydraulic drift of work equipment
Release of residual pressure from hydraulic circuit
Testing oil leakage
Bleeding air from various parts
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service
Undercarriage troubleshooting report
Failure codes table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Information contained in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution2
Failure code [989N00] Engine Controller Lock Caution3
Failure code [AA10NX] Air cleaner 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 Level 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 [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 Error56 topics
- 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 sensor high error
- Failure code [CA2272] EGR valve lift sensor low error
- Failure code [CA2351] EGR valve solenoid operation short circuit
- Failure code [CA2352] EGR valve solenoid operation disconnect
- Failure code [CA2555] Grid Htr Relay Volt Low Error
- Failure code [CA2556] Grid Htr Relay Volt High Error
- Failure code [D110KB] Battery Relay Drive S/C
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D862KA] GPS Antenna Discon
- Failure code [DA22KK] Pump Solenoid Power Low Error
- Failure code [DA25KP] 5V sensor power supply output 1 abnormality
- Failure code [DA29KQ] Model Selection Abnormality
- Failure code [DA2RMC] CAN discon (Pump con detected)
- Failure code [DAF8KB] Short circuit in camera power supply
- Failure code [DAFGMC] GPS Module Error
- Failure code [DGH2KB] Hydr Oil Sensor Short
- Failure code [DAFRMC] CAN discon (Monitor detected)
- 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 [DHX1MA] Overload Sensor Abnormality (Analog)
- 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 [DWA2KA] Service Sol Discon
Failure code [DWA2KB] Service Sol Short
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit
Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KB] 2-stage Relief Sol Short
Failure code [DXA0KA] PC-EPC Sol. Open Circuit
Failure code [DXA0KB] PC-EPC Sol. Short Circuit
Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE4KA] Service current EPC discon
Failure code [DXE4KB] Service current EPC short
Failure code [DY20KA] Wiper working abnormality
Failure code [DY20MA] Wiper parking abnormality
Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper drive (for) short
Failure code [DY2EKB] Wiper drive (rev) short
Before carrying out troubleshooting of electrical system
Engine does not start
Auto-decelerator does not operate
Automatic warming-up system does not operate
Preheater does not operate
All work equipment, swing, and travel mechanism do not move
Power maximizing function does not operate
Machine monitor does not display at all
Machine monitor does not display some items
Contents of display by machine monitor are different from applicable machine
Fuel level monitor was lighted in red while engine running
Engine coolant temperature gauge does not indicate normally
Hydraulic oil temperature gauge does not indicate normally
Fuel level gauge does not indicate normally
Swing lock monitor does not indicate normally
When monitor switch is operated, monitor displays nothing
Windshield wiper and window washer do not operate
Machine push-up function does not operate normally
Monitoring function fails to display “boom raise” normally
Monitoring function fails to display “boom lower” normally
Monitoring function fails to display “arm IN” normally
Monitoring function fails to display “arm OUT” normally
Monitoring function fails to display “bucket CURL” normally
Monitoring function fails to display “bucket DUMP” normally
Monitoring function fails to display “swing” normally
Monitoring function fails to display “travel” normally
Monitoring function fails to display “travel differential pressure” normally
Monitoring function fails to display “service” normally
KOMTRAX system does not operate normally
Air conditioner does not operate
Travel alarm does not sound or does not stop sounding
Horn does not sound52 topics
- System chart for hydraulic and mechanical system
- All work equipment lack power, or travel and swing speeds are slow
- Engine speed sharply drops or engine stalls
- No work equipment, swing or travel move
- Abnormal noise is heard from around hydraulic pump
- Auto-decelerator does not work
- Fine control mode does not function or responds slow
- Boom moves slowly or lacks power
- Arm moves slowly or lacks power
- Bucket moves slowly or lacks power
- Work equipment does not move in its single operation
- Work equipment has a bit too fast hydraulic drift
- Work equipment has big time lag
- Other work equipment moves when relieving single circuit
- Power max. switch does not operate
- Machine push-up function does not operate
- In compound operation of work equipment, speed of part loaded more is low
- When machine swings and raises boom simultaneously, boom rising speed is low
- When machine swings and travels simultaneously, travel speed lowers largely
- Machine deviates during travel
- Travel speed is low
- Machine is not steered well or steering power is low
- Travel speed does not change or travel speed is low or high
- Travel system does not move (only one side)
- Upper structure does not swing
- Swing acceleration or swing speed is low
- Upper structure overruns remarkably when it stops swinging
- Large shock is made when upper structure stops swinging
- Large sound is made when upper structure stops swinging
- Hydraulic drift of swing is large
- Attachment circuit is not changed
- Oil flow in attachment circuit cannot be controlled
- Method of using troubleshooting chart
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lacks output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
- Oil consumption is excessive (or exhaust smoke is blue)
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts back or coolant level goes down)
- Oil pressure drops
- Oil level rises (Entry of coolant or fuel)
- Coolant temperature becomes too high (overheating)
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tool 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 motor and swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller 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 anti-drop valve assembly for boom
Removal and installation of anti-drop valve assembly for arm
Disassembly and assembly of anti-drop valve assembly
Removal and installation of operator cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller
Hydraulic circuit diagram2 topics
- Electrical circuit diagram
- Connector list and stereogram
Inside this manual
Real pages from this service manual (1,079 pages). Open the sample pages (PDF, 790 KB)
- Diagram, page 510: Related circuit diagram
- Troubleshooting, page 702: Failure code [DHPAMA] F Pump Press Sensor Abnormality
- Specifications, page 926: 50 Disassembly and assembly
- Foldout diagram, page 1,073: Electrical circuit diagram (2/5)
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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, 1,079 pages
Quantity one is the manual described above.
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Other editions and similar models
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