Komatsu™ PC400, PC400LC-7, PC450, PC450LC-7 manual, covers 2003-2007

Komatsu PC400/PC450 Series Shop Manual - 2003 Edition

Engineered for high-performance excavation, this factory shop manual provides the essential technical infrastructure for maintaining the PC400 and PC450 series machines. Precise adherence to the 33-liter swing circle grease requirement using G2-LI lithium lubricant is critical for uptime, as it ensures the structural integrity of the inner race and ball bearings under high-frequency rotation. Technical personnel will find that following these calibrated benchmarks directly correlates to extended component life and reduced parasitic power loss across the hydraulic circuit.

Technical Applicability & Serial Ranges

PC400 Series Hydraulic Excavators

• PC400-7: Serial Number 50001 and up
• PC400LC-7 (Long Undercarriage): Serial Number 50001 and up

PC450 Series Hydraulic Excavators

• PC450-7: Serial Number 20001 and up
• PC450LC-7 (Long Undercarriage): Serial Number 20001 and up

Operational Parameters & Service ROI

• Implementation of the 37.8 MPa {380 kg/cm²} main relief set pressure maximizes breakout force while staying within safety design limits.
• Precise monitoring of the 228 mm link pitch allows for accurate undercarriage wear analysis and scheduled pin-and-bushing rotations.
• Integration of CLSS (Closed-center Load Sensing System) data enables optimized engine-pump matching for superior fuel economy.

Technical Document Metadata

• Print Number: SEBM033000
• Total Pagination: 215 Pages
• Engine Configuration: SAA6D125E-3 (Low Emission Type)

System Architecture & Factory Benchmarks

Hydraulic power is delivered through the HPV190+190 variable displacement piston pump system, capable of a dual delivery of 345 liters per minute. The SAA6D125E-3 power plant features a flywheel output of 246.4 kW {330 HP} at 1,850 rpm, governed by an electronic control system that balances torque demand with fuel consumption. Component weight management is facilitated by the provided data, such as the 1,500 kg engine assembly and 9,220 kg counterweight, which are vital for safe lifting and transport planning.

Visual Navigation Aids

• Hydraulic Circuitry: Comprehensive schematics (SJP10040) detailing the PPC lock, 2-stage relief, and pump merge/divider solenoid loops.
• Cross-Sectional Analysis: Internal views of the KMV200ADT-2 travel motor and KMF230ABE-5 swing motor showing brake and safety valve locations.
• Electronic Mapping: Pin-out diagrams for the CN-E11, CN-E12, and CN-E13 engine control connectors.

Table of Contents

• 01 General: Dimensions, specifications, weight tables, and lubricant capacities.
• 10 Structure, Function and Maintenance Standard:
  • Engine Related Parts and Damper Assembly
  • Radiator, Oil Cooler, and Aftercooler
  • Power Train: Final Drive, Swing Machinery, and Swing Circle
  • Undercarriage: Track Frame, Recoil Spring, Idlers, and Rollers
  • Hydraulic System: Pump (HPV160/190), LS(PC)-EPC Valves, and Control Valve
  • Work Equipment: Boom, Arm, and Bucket Cylinder maintenance standards
  • Electronic Control System: Engine/Pump control functions and Auto-deceleration
  • Monitor System: Panel outlines and maintenance interval tracking
• 90 Others: Detailed Hydraulic and Electrical Circuit Diagrams.

Operational Limits & Specifications

• Relief Cracking Pressure (Hydraulic Tank): 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm²}
• Swing Motor Safety Valve: 27.9 MPa {285 kg/cm²}
• Track Shoe Bolt Torque: 393 ± 39 Nm {40 ± 4 kgm} plus 120° ± 10° additional turn.
• Service Capacities: Engine Oil Pan (38 L), Final Drive (12 L per side), Hydraulic System (248 L refill).