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Shop
Manual
PC400LC-7L
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
PC400LC-7L
A86001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
May 2004
Printed in USA
PC400LC-7L
FOREWORD
12
CONTENTS
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
20
30
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 2
PC400LC-7L
FORM NUMBER
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM012502
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM024208
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HE03-2
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
PC400LC-7L R02 pubinfok.fm
5/19/04
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SHIP TO
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ONLY
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PUBLICATION
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FOREWORD
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PC400LC-7L
FOREWORD
SAFETY
12
SAFETY
00
SAFETY NOTICE
00
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols
and
are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with
buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding
work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting.
Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's compartment.
5.
Keep all tools in good condition and learn the correct way to use them.
6.
Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct
places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
00
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the
control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
PC400LC-7L
00-3
FOREWORD
4.
SAFETY
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.
00
1.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-)
terminal first.
4.
When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing
electrical parts.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4
PC400LC-7L
FOREWORD
GENERAL
12
GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This 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.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
PC400LC-7L
00-5
FOREWORD
12
00
00
REVISIONS
00
SYMBOLS
00
Symbol
1.
2.
Safety
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
00
See the page number on the bottom of the page. File the
pages in correct order.
Following examples show how to read the page number:
Example:
10 - 3
Item number (10. Structure and Function)
Consecutive page number for each item
3.
Remarks
00
FILING METHOD
Item
10-4
10-4-1
10-4-2
Added pages
10-5
00
00-6
PC400LC-7L
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
00
1.
2.
WIRE ROPES
1.
3.
00
Wire Ropes
(Standard Z or S twist ropes without galvanizing)
Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
4.
PC400LC-7L
00-7
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
The recommended coating materials prescribed in the shop manuals are listed below.
Category
Code
Adhesives
LT-1A
Part No.
790-129-9030
Quantity
Container
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pes.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive: 1 kg
Hardening
agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
2g
Polyethylene
container
Aron-alpha
790-129-9130
201
50 g
Polyethylene
container
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
Three bond
179-129-9140
1735
Gasket sealant
00-8
790-129-9070
1 kg
LG-3
Can
PC400LC-7L
FOREWORD
Category
Code
COATING MATERIALS
Part No.
Quantity
Container
LG-4
790-129-9020
200 g
Tube
Gasket sealant
LG-5
790-129-9080
1 kg
Polyethylene
container
LG-6
09940-00011
250 g
Tube
150 g
Tube
Three bond
790-129-9090
1211
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
09920-00150
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYG2-160CNCA
Various
Various
Belows type
Molybdenum
disulphide lubricant
Grease
Molybdenum
disulphide
lubricant
LG-7
PC400LC-7L
SYG2-400M
00-9
FOREWORD
12
00
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
mm
mm
Nm
lbf ft
10
13.2 1.4
9.2 1.03
13
31.4 2.9
23.1 2.1
10
17
65.7 6.8
48.4 5.0
12
19
112 9.8
82.6 7.2
14
22
177 19
130.5 14.0
16
24
279 29
205.7 21.3
18
27
383 39
282.4 28.7
20
30
549 58
404.9 42.7
22
32
745 78
549 57.5
24
36
927 98
683 72.2
27
41
1320 140
973.5 103.2
30
46
1720 190
1268.6 140.1
33
50
2210 240
1630.0 177.0
36
55
2750 290
2028.2 213.8
39
60
3280 340
2419.2 250.7
mm
mm
Nm
lbf ft
10
7.85 1.95
5.7 1.4
13
18.6 4.9
13.7 3.6
10
14
40.2 5.9
29.6 4.3
12
27
82.35 7.85
60.7 5.7
00-10
PC400LC-7L
FOREWORD
12
TIGHTENING
00
mm
mm
Nm
lbf ft
02
14
19
24.5 4.9
18.0 3.6
03
18
24
49 19.6
36.1 14.4
04
22
27
78.5 19.6
57.8 14.4
05
24
32
137.3 29.4
101.2 21.6
06
30
36
176.5 29.4
130.1 21.6
10
33
41
196.1 49
144.6 36.1
12
36
46
245.2 49
180.8 36.1
14
42
55
294.2 49
216.9 36.1
Nominal No.
Tightening torque
00
Tightening torque
mm
mm
Nm
lbf ft
10
14
65.7 6.8
48.4 5.0
12
17
112 9.8
82.6 7.2
16
22
279 29
205.7 21.3
00
Thread diameter
mm
mm
Nm
lbf ft
14
19
24.5 4.9
18.0 3.6
18
24
49 19.6
36.1 14.4
22
27
78.5 19.6
57.8 14.4
24
32
137.3 29.4
101.2 21.6
30
36
176.5 29.4
130.1 21.6
33
41
196.1 49
144.6 36.1
36
46
245.2 49
180.8 36.1
42
55
294.2 9
216.9 36.1
PC400LC-7L
Tightening torque
00-11
FOREWORD
12
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example:
05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire
Nominal
number
Cable O.D.
(mm)
Current
rating (A)
Applicable circuit
0.88
2.4
12
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Number of
strands
Dia. Of strand
(mm)
Cross section
(mm)
0.85
11
0.32
26
Circuits
Classification
Primary
Priority
00-12
Auxiliary
00
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
Color
Black &
White
Green &
White
Code
WB
BY
RB
YB
GR
LR
Color
White &
Black
Black &
Yellow
Yellow &
Black
Code
WL
BR
RY
YG
GY
LY
Color
Red &
Yellow
Yellow &
Green
Blue &
Yellow
Code
WG
RG
YL
GB
LB
Color
White &
Green
Yellow &
Blue
Green &
Black
Code
RL
YW
GL
Color
Yellow &
White
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
CONVERSION TABLES
00
00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2.
2
Millimeters to inches
1 mm = 0.03937 in
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
3
1
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
PC400LC-7L
00-13
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
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
00-14
1 kg = 2.2046 lb
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
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
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
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
PC400LC-7L
00-15
FOREWORD
CONVERSION TABLES
12
00-16
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
1352.63
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
PC400LC-7L
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233lb/in2
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
PC400LC-7L
00-17
FOREWORD
CONVERSION TABLES
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
C
-40.4
-37.2
-34.4
-31.7
-28.9
-40
.35
-30
-25
-20
F
-40.0
-31.0
-22.0
-13.0
-4.0
C
-11.7
-11.1
-10.6
-10.0
-9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
-28.3
-27.8
-27.2
-26.7
-26.1
-19
-18
-17
-16
-15
-2.2
-0.4
1.4
3.2
5.0
-8.9
-8.3
-7.8
-7.2
-6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
-25.6
-25.0
-24.4
-23.9
-23.3
-14
-13
-12
-11
-10
6.8
8.6
10.4
12.2
14.0
-6.1
-5.6
-5.0
-4.4
-3.9
21
22
23
24
25
-22.8
-22.2
-21.7
-21.1
-20.6
-9
-8
-7
-6
-5
15.8
17.6
19.4
21.2
23.0
-3.3
-2.8
-2.2
-1.7
-1.1
-20.0
-19.4
-18.9
-18.3
-17.8
-4
-3
-2
-1
0
24.8
26.6
28.4
30.2
32.0
-17.2
-16.7
-16.1
-15.6
-15.0
1
2
3
4
5
-14.4
-13.9
-13.3
-12.8
-12.2
6
7
8
9
10
00-18
46
47
48
49
50
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
F
117.8
179.6
181.4
183.2
185.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
-0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
PC400LC-7L
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
PC400LC-7L
01-1
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS
Item
Operating weight
(Variable gauge specification)
Operating weight
(Fixed gauge specification)
Unit
kg
(lb)
Operating weight
Bucket capacity
Name of engine
Rated horsepower of engine
A Overall length
B Overall height
Overall width
(Variable gauge specification)
Overall width
C
(Fixed gauge specification)
01-2
m3
(cu.yd)
kW
(HP)/rpm
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
km/h
(MPH)
rpm
F/G
V/G
F/G
V/G
PC400LC-7L
44,600
(98,343)
43,700
(96,359)
43,700
(96,359)
1.9
(2.5)
KOMATSU SAA6D125E-3 diesel engine
246(330)
/1,850
12,040
(39' 6)
3,670
(12')
3,690
(12' 1.2)
3,640
(11' 11.3)
800
(2' 7.5)
900
(2' 11.4)
3,250
(10' 8)
3,645
(11' 12)
5,355
(17 7)
4,350
(14' 3)
685
(2' 3)
3.0/4.4/5.5
(1.9/2.7/3.4)
9.1
2740
2890
--2392
PC400LC-7L
GENERAL
SPECIFICATIONS
12
Variable gauge specification means the machine can extend and retract overall width (C) of the track frame.
Fixed gauge specification means the machine cannot extend or retract overall width (C) of the track frame.
01-3
PC400LC-7L
GENERAL
SPECIFICATIONS
12
Working ranges
A Max. digging reach
B Max. digging depth
C Max. digging height
D Max. vertical wall digging depth
E Max. dumping height
F Min. dump height
G Max. digging reached at ground level
01-4
Unit
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
mm
(ft in)
PC400LC-7
12,030
(39' 6)
7,830
(25' 8)
10,930
(35' 10)
6,870
(22' 6)
7,625
(25')
11,820
(38' 9)
PC400LC-7L
GENERAL
SPECIFICATIONS
12
Machine model
PC400LC-7L
Serial Number
A86001 and UP
Bucket capacity
Performance
Weight of machine
Max. digging force
(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
Dimensions
Ground pressure
(standard shoe width)
Overall length (for transport)
Overall width
Overall width of track (for transport)
Overall width of track when extended
Overall height (for transport)
Overall height to top of machine
Ground clearance of upper structure
Min. ground clearance
Tail swing radius
Min. swing radius of work equipment
Height of work equipment at min. swing radius
Length of track on ground
Track gauge (Tg)
Track gauge (for transport)
Height of machine cab
kg
lb
kgf (lbf)
kgf (lbf)
rpm
deg.
km/h (mi/h)
deg.
Performance
Engine
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption
43,700
96,342
44,600
98,326
26,100 (57,541)
28,000 (61,729)
9.1
20
Lo: 3.0 (0.00186), Mi: 4.4 (0.00273),
Hi: 5.5 (0.00341)
35
kg/cm2 (lbf/ft2)
mm (in)
0.82 (11.66)
900 (35.4)
0.67 (9.52)
800 (31.5)
mm (ft in)
mm (in)
L (in3)
SAA6D125E-3
4-cycle, water-cooled, in-line, vertical, direct
injection, with turbocharger and aftercooler
6 - 125x150 (6 - 4.921x5.905)
11.045 (674.007)
kW/rpm (HP/rpm)
kgm/rpm (lbf ft/rpm)
rpm
rpm
g/kWh (g/HPh)
246.4/1,850 (330/1,850)
136/1,400 (983.9/rpm)
1,930
1,000
203 (151)
Model
Type
No. of cylinders - bore x stroke
Piston displacement
1.4
1.83
m3
yd3
Starting motor
Alternator
Battery
Radiator core type
24 V, 11 Kw
24 V, 50 A
12 V, 110 Ahx2
ALW-4
PC400LC-7L
01-5
GENERAL
SPECIFICATIONS
Carrier roller
2 on each side
Track roller
8 on each side
Track shoe
Hydraulic pump
Control valve
Type x No.
Type x No.
Hydraulic motor
Hydraulic system
Undercarriage
12
Travel motor
Swing motor
Delivery
Set pressure
L/min (in3)
345x2 (21053.2)
kgf/cm2 (lbf/in2)
380 (5404.87)
6-spool type + 1-spool type x 1
Control method
Hydraulic
Hydraulic cylinder
Boom
Type
Inside diameter of cylinder
Diameter of piston rod
Stroke
Max. distance between pins
Min. distance between pins
Hydraulic tank
Hydraulic filter
Hydraulic cooler
01-6
Arm
Bucket
Double-acting piston
mm (ft in)
160 (0 6")
110 (0 4")
1,570 (5 2")
3,830 (12 7")
2,260 (7 5")
185 (0 7")
120 (0 5")
1,820 (6 0")
4,325 (14 2")
2,505 (8 3")
160 (0 6")
110 (0 4")
1,270 (4 2")
3,140 (10 4")
1,870 (6 2")
PC400LC-7L
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE
WARNING! This weight table is for use when handling components or when transporting the machine
Unit: kg (lb)
Engine assembly
Engine
Damper
Hydraulic pump
1,500 (3,307)
1,150 (2,535)
14.7 (32)
210 (463)
195 (430)
198 (437)
251 (554)
Revolving frame
3,297 (7,269)
Operators cab
279 (616)
Operators seat
35 (78)
Counterweight
9,500 (20,944)
526 (1,160)
257 (567)
Swing motor
105 (232)
Travel motor
208 (459) x 2
Center frame
Crawler frame
Swing circle
Idler
Idler cushion
Carrier roller
Track roller
Final drive (including travel motor)
40 (89)
Fixed gauge specification
10,965 (24,174)
6,077 (13,398)
-----
11,934 (26,310)
7,096 (15,644)
3,229 (7,119)
1,921 (4,235) x 2
605 (1,334) x 2
230 (507) x 2
338 (745) x 2
32 (71) x 4
72 (159) x 16
722 (1,592) x 2
4,760 (10,494)
5,210 (11,486)
5,670 (12,500)
6,130 (13,515)
Boom assembly
3,290 (7,254)
Arm assembly
1,374 (3,030)
Bucket assembly
1,366 (3,012)
355 (783) x 2
PC400LC-7L
510 (1,125)
01-7
GENERAL
WEIGHT TABLE
280 (618)
Link assembly
258 (569)
Boom pin
Arm pin
Bucket pin
38 (102) x 2
Link pin
34 (75) x 2
01-8
PC400LC-7L
GENERAL
12
RESERVOIR
KIND OF
FLUID
AMBIENT TEMPERATURE
-22 -4
-30 -20
14
-10
32
0
50
10
68
20
86 104F
30
40C
CAPACITY - L (gal)
Specified
Refill
42 (11.09)
38 (10.03)
1.07 (0.282)
---
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Damper case
Swing machinery case
Final drive case (each side)
13.4 (3.53)
Engine
oil
SAE 30
Idler (1 each)
12 (3.17)
0.335-0.355 (0.0884-0.0937)
0.28-0.31 (0.0739-0.0818)
0.12-0.18 (0.0317-0.0475)
SAE 10W
SAE 10W-30
Hydraulic system
SAE 15W-40
Hydraulic
oil
Fuel tank
Cooling system
Diesel
fuel
Coolant
472 (124.6)
248 (65.5)
650 (171.7)
---
36 (9.51)
---
H046-HM (H)
ASTM D975 No. 2
Add antifreeze
PC400LC-7L
01-9
GENERAL
12
MEMORANDUM
01-10
PC400LC-7L
10
12
RADIATOR OIL COOLER AFTERCOOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
CARRIER ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
TRIPLE GROUSER SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
HYDRAULIC PIPING DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
LS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
LS(PS)-EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
VARIABLE VOLUME VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
SELF PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
REVERSAL PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
TRAVEL JUNCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
TRAVEL PPC SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
WORK EQUIPMENT SWING PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
SERVICE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
PPC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
RETURN OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
BOOM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
ARM HYDRAULIC DRIFT PREVENTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
LIFT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
ATTACHMENT CIRCUIT SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PC400LC-7L
10-1
TABLE OF CONTENTS
10-2
PC400LC-7L
12
1.
Oil cooler
7.
Specifications
2.
Radiator
8.
Radiator: ALW-4
3.
Radiator cap
9.
Aftercooler
4.
Reservoir tank
10. Condenser
5.
Net
6.
Shroud
PC400LC-7L
10-3
POWER TRAIN
12
POWER TRAIN
1.
10-4
Idler
7.
2.
8.
3.
Control valve
9.
4.
Final drive
5.
6.
Engine (SAA6D125-3E)
PC400LC-7L
FINAL DRIVE
12
FINAL DRIVE
PC400LC-7L
10-5
FINAL DRIVE
12
1.
Level plug
2.
Drain plug
3.
4.
5.
6.
7.
8.
Cover
9.
10. Sprocket
11. Floating seal
12. Travel motor
13. No. 2 planetary gear (No. of teeth: 38)
Specification
Reduction ratio:
-((10 + 98)/10)x((18+98)/18)=-68.600
Unit: mm
No.
Check item
Criteria
Remedy
14
Standard clearance
Clearance limit
0.15 - 0.54
1.10
15
0.18 - 0.66
1.30
16
0.06 - 0.24
---
17
0.15 - 0.51
1.00
18
0.17 - 0.60
1.20
19
0.15 - 0.54
---
20
21
22
Bolt
23
Repair limit: 6
Standard size
Repair limit
90
87
Torque Nm
Torque lbf ft
59 - 78
44 - 57
Bolt
98 - 123
73 - 90
24
Bolt
59 - 74
44 - 54
25
Bolt
640 - 785
473 - 578
26
Bolt
490 - 608
362 - 448
10-6
Replace
Rebuild or replace
PC400LC-7L
SWING MACHINERY
12
SWING MACHINERY
PC400LC-7L
10-7
SWING MACHINERY
12
1.
2.
Cover
3.
Case
4.
5.
6.
Ring gear
7.
8.
Swing motor
9.
Unit: mm
No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.18 - 0.28
---
14
15
0.15 - 0.51
1.00
16
0.17 - 0.60
1.10
17
0.40 - 0.75
1.20
18
0.16 - 0.55
1.00
19
0.17 - 0.60
1.10
20
0.08 - 0.25
---
21
0.00 - 1.21
2.00
22
0.57 - 1.09
---
23
Standard size
Repair limit
24
Bolt
25
0
150 -0.100
---
Torque Nm
Torque lbf ft
824 - 1030
608 - 759
Bolt
343 - 427
253 - 314
26
Bolt
98 - 123
73 - 90
27
Bolt
245 - 309
181 - 228
28
Bolt
2.81 - 3.79
2.07 - 2.79
10-8
Replace
PC400LC-7L
SWING CIRCLE
12
SWING CIRCLE
1.
Specification
2.
Ball
3.
a.
b.
Unit: mm
No.
4
Check item
Axial clearance of bearing (when mounted on
chassis)
PC400LC-7L
Criteria
Remedy
Standard clearance
Repair limit
0.5 - 1.6
3.2
Replace
10-9
12
1.
Idler
2.
Track frame
3.
Carrier roller
4.
Final drive
5.
Track roller
6.
Track shoe
7.
Center guard
8.
Recoil spring
9.
Front guard
10-10
The dimensions and the number of track rollers depend on the model, but the basic
structure is not different.
Number of track rollers: 8
PC400LC-7L
12
Item
Fixed gage
Variable gage
Shoe width
900 mm
800 mm
Link pitch
228 mm
228 mm
49 (Pieces)
49 (Pieces)
Unit: mm
No.
10
11
Check item
Criteria
Remedy
Standard
size
Tolerance
Track frame
123
+2
-1
127
Idler support
120
0.5
118
Track frame
266
+3
-1
271
Idler support
261
---
259
Standard size
12
Recoil spring
PC400LC-7L
Repair limit
Freelength x
OD
Installation
length
Installation
load
Free length
Installation
load
795 x 241
648
173.3 kN
{17,680 kg}
---
138.56 kN
{14,140 kg}
Replace
10-11
IDLER
12
IDLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
704
---
660
648
Depth of tread
22
28
Total width
202
---
Width of tread
48.5
---
Standard size
6
Bolt
10-12
Tolerance
Rebuild or
replace
Shaft
Hole
Standard
clearance
-0.120
-0.207
+0.360
+0.220
0.340-0.507
Tolerance
Shaft
Hole
Standard
interference
+0.087
+0.037
-0.027
-0.079
0.064-0.149
Torque Nm
Torque lbf ft
130 - 180
96 - 132
Replace
bushing
PC400LC-7L
CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
175
---
148
134
Width of tread
50.3
---
Thickness of tread
32
25
Width of flange
19
7
8
PC400LC-7L
--Tolerance
Interference Replace
limit
Standard
size
Shaft
Hole
Standard
interference
50
-0.250
-0.270
+0.099
-0.032
0.218 - 0.369
57
+0.117
+0.087
+0.040
0
0.047 0.177
---
Standard clearance
Clearance limit
0.5 - 0.7
---
10-13
TRACK ROLLER
12
TRACK ROLLER
10-14
PC400LC-7L
TRACK ROLLER
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
---
237
---
200
188
Thickness of tread
56.2
50.2
Overall width
278
---
Singe flange
54.6
---
Double flange
51.6
---
Singe flange
32.6
---
Double flange
32.6
---
23.0
---
0.4 - 1.0
---
Width of tread
Width of outer
flange
Axial play
10
11
Tolerance
Standard
size
Shaft
Hole
Standard
clearance
Clearance
limit
80
-0.250
-0.350
+0.174
+0.029
0.279 -0.524
1.5
87.6
+0.108
+0.008
-0.006
-0.036
Standard
interference
Interference
limit
0.014-0.144
---
Torque Nm
Replace bushing
Torque lbf ft
12
Bolt
10 - 20
8 - 14
13
Bolt
1st torque
200 20
147 14
13
Bolt
2nd torque
105 5
77 3
PC400LC-7L
Rebuild or replace
10-15
TRACK SHOE
12
TRACK SHOE
10-16
PC400LC-7L
TRACK SHOE
12
Unit: mm
No.
1
Check item
Link pitch
Link height
6
7
Standard size
Repair limit
228.9
231.9
Standard size
When turned
71.5
66.5
12
Standard size
Repair limit
129
119
34.5
24.5
Reverse or replace
Adjust or replace
Repair or replace
144
Replace
76.2
9
Link
11
Inside width
106
Overall width
51.6
Tread width
44.8
12
Protrusion of pin
4.4
13
5.25
14
252
15
16
Thickness of spacer
17
18
Remedy
184
8
10
Criteria
Press-fitting force
19
Repair or replace
Adjust or replace
164.5
---
Bushing
Regular pin
Master pin
---
PC400LC-7L
10-17
TRACK SHOE
12
Unit: mm
No.
Check item
Criteria
a. Regular link
20
Tightening torque
(Nm {lbf ft})
Triple shoe
Shoe bolt
b. Master link
39339
{28928}
---
22
23
Standard size
---
Tolerance
Standard interference
Hole
71
+0.494
+0.454
+0.074
0
0.380 - 0.494
47
+0.235
+0.085
-0.218
-0.280
0.303 - 0.515
Standard size
Standard size
Standard size
47
10-18
---
Shaft
47
25
Retighten
49
47
24
12010
21
Remedy
Tolerance
Shaft
Standard clearance
Hole
+0.235
+0.085
+0.915
+0.415
Tolerance
Shaft
Hole
+0.03
0
-0.218
-0.280
Tolerance
Shaft
Hole
-0.2
-0.4
+0.915
+0.415
Adjust or
replace
0.180 - 0.830
Standard interference
0.218 - 0.310
Standard clearance
0.615 - 1.315
PC400LC-7L
TRACK SHOE
GROUSER SHOE
Unit: mm
No.
Check item
Height
Thickness
3
4
Length at of base
5
6
Criteria
Remedy
Standard size
Repair limit
37
22
13
33
27
Rebuild or replace
25.5
Length at tip
PC400LC-7L
17.5
23.5
10-19
HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM
HYDRAULIC PIPING DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding valve
19. Accumulator
20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Travel junction solenoid
20C. Pump merge/divider solenoid
20D. Travel speed solenoid
20E. Swing brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid
10-20
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-21
HYDRAULIC SYSTEM
TANK
1.
Specifications
2.
Breather
3.
Hydraulic tank
4.
Sight gauge
Pressure valve
5.
Strainer
6.
Filter element
7.
Strainer
Bypass valve set pressure: 1.5 0.3 kg/cm2 (21.3 4.26 psi)
8.
Bypass valve
Breather
Intake valve set pressure: 0.02 0.003 kg/cm2 (0.284 0.0426 psi)
Exhaust valve set pressure: 1.0 0.15 kg/cm2 (14.2 2.13 psi)
10-22
PC400LC-7L
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-23
HYDRAULIC SYSTEM
PUMP
HPV160+160(190)
IM
PENR
ISIG
PLSF
3. LS valve
PAF
PLSFC
4. PC valve
PFC
PLSR
5. LS-EPC valve
PAR
PLSRC
6. PC-EPC valve
PRC
PS
: Pump suction
PBF
PLSCR:
PD1F
PM
PENF
PBR
PDIR
: Air bleeder
PD2F
: Drain plug
PEPB
PD2R
: Drain plug
Outline
This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve.
10-24
PC400LC-7L
HYDRAULIC SYSTEM
12
1.
Shaft (Front)
4.
Rocker cam
7.
Cylinder block
2.
Cradle
5.
Shoe
8.
Valve plate
3.
Case (Front)
6.
Piston
9.
End cap
Torque Nm
Torque lbf ft
58.8 - 78
43.3 - 57.5
14.
132 - 157
97.3 - 115.7
20.
7.8 - 9.8
5.7 - 7.2
15.
11.8 - 14.7
8.7 - 10.8
21.
637 - 764.4
470 - 563.7
13.
19.
Torque Nm
Torque lbf ft
18.6 - 23.5
13.7 - 17.3
16.
6.9 - 9.8
5.0 - 7.2
22.
246.3 - 308.7
181.7 - 227.6
17.
98.1 - 122.6
72.3 - 90.4
23.
27 - 34
119.9 - 25.0
18.
19.6 - 27.4
14.5 - 20.2
24.
343 - 427
253 - 314
PC400LC-7L
10-25
HYDRAULIC SYSTEM
12
Function
The rotation and torque transmitted to the pump shaft are converted into hydraulic energy, and pressurized oil is
discharged according to the load.
It is possible to change the discharge amount by changing the swash plate angle.
Structure
Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings.
The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a
spherical bearing.
Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular
movement. Rocker cam (4) brings high pressure oil at cylinder surface B with cradle (2), which is secured to the case, and
forms a static pressure bearing when it slides.
Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
10-26
PC400LC-7L
HYDRAULIC SYSTEM
12
Operation
1.
Operation of pump
A. Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface A. When this happens, rocker cam (4) moves
along cylindrical surface B, so angle between center line X of
rocker cam (4) and the axial direction of cylinder block (7)
changes. (Angle is called the swash plate angle.)
B. Center line X of rocker cam (4) maintains swash plate angle in
relation to the axial direction of cylinder block (7), and flat
surface A moves as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of cylinder block (7), so
a difference between volumes E and F is created inside cylinder
block (7). The suction and discharge is carried out by this
difference F E.
In other words, when cylinder block (7) rotates and the volume of
chamber E becomes smaller, the oil is discharged during that
stroke. On the other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, the oil is sucked in.
C. If center line X of rocker cam (4) is in line with the axial direction
of cylinder block (7) (swash plate angle = 0), the difference
between volumes E and F inside cylinder block (7) becomes 0, so
the pump does not carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never becomes 0.)
PC400LC-7L
10-27
HYDRAULIC SYSTEM
12
2. Control of discharge amount
If the swash plate angle becomes larger, the difference between
volumes E and F becomes larger and discharge amount Q
increases.
Swash plate angle is changed by servo piston (12).
Servo piston (12) moves in a reciprocal movement () according
to the signal pressure from the PC and LS valves. This straight
line movement is transmitted through rod (13) to rocker cam (4),
and rocker cam (4), which is supported by the cylindrical surface
to cradle (2), slides in a rotating movement in direction of arrow.
10-28
With servo piston (12), the area receiving the pressure is different
on the left and the right, so main pump discharge pressure (self
pressure) PP is always brought to the chamber receiving the
pressure at the small diameter piston end.
Output pressure Pen of the LS valve is brought to the chamber
receiving the pressure at the large diameter end. The relationship
in the size of pressure PP at the small diameter piston end and
pressure Pen at the large diameter end, and the ratio between the
area receiving the pressure of the small diameter piston and the
large diameter piston controls the movement of servo piston (12).
PC400LC-7L
HYDRAULIC SYSTEM
VALVE
1. Plug
PA
: Pump port
2. Locknut
PP
: Pump port
3. Sleeve
PDP
: Drain port
4. Spring
PLP
5. Seat
PLS
6. Spool
PPL
7. Piston
PSIG
8. Sleeve
PC VALVE
PA
: Pump port
2. Plug
PA2
3. Pin
PDP
: Drain port
4. Spool
PM
5. Retainer
PPL
6. Seat
7. Cover
8. Wiring
PC400LC-7L
10-29
HYDRAULIC SYSTEM
12
Function
1.
LS valve
The LS valve detects the load and controls the discharge amount.
This valve controls main pump discharge amount Q according to
differential pressure PLS (=PP PLS) [called the LS differential
pressure] (the difference between main pump pressure PP and control
valve outlet port pressure PLS).
Main pump pressure PP, pressure PLS {called the LS pressure}
coming from the control valve output, and pressure PSIG {called the
LS selector pressure} from the proportional solenoid valve enter this
valve. The relationship between discharge amount Q and differential
pressure PLS, (the difference between main pump pressure PP and
LS pressure PLS) (= PP PLS) changes as shown in the diagram at the right according to LS pressure selector current
PSIG of the LS-EPC valve.
When PSIG changes between 0 and 1A, the set pressure of the spring changes according to this, and the selector point for
the pump discharge amount changes at the rated central valve between 12 27 kg/cm2 (170.6 384.0 psi).
2.
PC valve
When the pump discharge pressure PP1 (self pressure) and PP2 (other
pump pressure) are high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In
this way, it carries out equal horsepower control so that the horsepower
absorbed by the pump does not exceed the engine horsepower.
In other words, If the load during the operation becomes larger and the
pump discharge pressure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure drops, it increases the
discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge
amount of F, R pumps (PP1 + PP2)/2) and pump discharge amount Q
is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The controller senses
the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge
amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set
value, the command current to the PC-EPC valve solenoid from the controller increases according to the drop in the
engine speed to reduce the pump swash plate angle.
10-30
PC400LC-7L
HYDRAULIC SYSTEM
OPERATION
1.
LS valve
A. When control valve is at neutral position
The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control
valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The
size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC
valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring
changes).
PC400LC-7L
10-31
HYDRAULIC SYSTEM
12
10-32
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-33
HYDRAULIC SYSTEM
12
10-34
PC400LC-7L
HYDRAULIC SYSTEM
12
2.
PC Valve
A. When pump controller is normal
i.
When the load on the actuator is small and pump pressures PP1 and PP2 are low
a. Movement of PC-EPC solenoid (1)
The command current from the pump controller flows to PC-EPC solenoid (1).This command current
acts on the PC-EPC valve and outputs the signal pressure. When this signal pressure is received, the force
pushing piston (2) is changed.
On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6)
and pump pressure PP1 (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops
at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port
C) output from the PC valve changes according to this position.
The size of command current X is determined by the nature of the operation (lever operation), the
selection of the working mode, and the set value and actual value for the engine speed.
Other pump pressure
This is the pressure of the pump at the opposite end.
For the F pump, it is the R pump pressure
For the R pump, it is the F pump pressure
PC400LC-7L
10-35
HYDRAULIC SYSTEM
12
b. Action of spring
The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position.
If piston (9) moves to the right, spring (6) is compressed, and if it moves further to the right, spring (6)
contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (9)
extending or compressing springs (4) and (6).
If the command circuit input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2)
changes, and the spring load of springs (4) and (6) also changes according to the valve of the PC-EPC
valve solenoid command current.
Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self pressure PP1 enters
port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A.
When pump pressures PP1 and PP2 are small, spool (3) is on the left. At this point, port C and D are
connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the
LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from
port J becomes drain pressure PT, and servo piston (9) moves to the left. In this way, the pump discharge
amount moves in the direction of increase.
As servo piston (9) moves further, springs (4) and (6) expand and the spring force becomes weaker.
When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C
and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure
at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of
piston (9) to the left is stopped.
In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where
the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing
force created by the pressures PP1 and PP2 acting on the spool (3) are in balance.
10-36
PC400LC-7L
HYDRAULIC SYSTEM
12
ii.
PC400LC-7L
10-37
10-38
HYDRAULIC SYSTEM
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-39
HYDRAULIC SYSTEM
12
ii.
10-40
PC400LC-7L
HYDRAULIC SYSTEM
VALVE
1. Body
5. Coil
PSIG
: To LS(PC) valve
2. Spool
6. Plunger
PT
: To tank
3. Spring
7. Connector
PEPC
4. Rod
PC400LC-7L
10-41
HYDRAULIC SYSTEM
12
Function
The EPC valve consists of the proportional solenoid portion and the
hydraulic valve portion.
When it receives signal current i from the pump controller, it
generates the EPC output pressure in proportion to the size of the
signal, and outputs it to the LS valve.
Operation
1.
10-42
PC400LC-7L
HYDRAULIC SYSTEM
12
2. When signal current is very small (coil energized)
When a very small signal current flows to coil (5), coil (5) is
energized, and a propulsion force is generated which pushes
plunger (6) to the left.
Push pin (4) pushes spool (2) to the left, and pressurized oil flows
from port PEPC to port PSIG(PM).
When the pressure at port PSIG(PM) rises and the load of spring
(3) + the force acting on surface a of spool (2) becomes greater
than the propulsion force of plunger (6), spool (2) is pushed to the
right. The circuit between port PEPC and port PSIG(PM) is shut
off, and at the same time, port PSIG(PM) and port PT are
connected.
As a result, spool (2) is moved up or down until the propulsion
force of plunger (6) is balanced with the load of spring (3) +
pressure of port PSIG(PM).
Therefore, the circuit pressure between the EPC valve and the LS
valve is controlled in proportion to the size of the signal current.
3.
PC400LC-7L
10-43
HYDRAULIC SYSTEM
VOLUME VALVE
1. Block
PM
: To PC valve
2. Plug
PT
: To tank
3. Spring
PEPC
4. Piston
10-44
PC400LC-7L
HYDRAULIC SYSTEM
12
Function
Operation
The output pressure from EPC flows to port PM, and when the
propulsion force of piston (4) becomes larger than the load of spring
(3), piston (4) is pushed to the left and the volume at port PM
increases.
When the propulsion force of piston (4) becomes less than the load on
spring (3), piston (4) is pushed to the right and the volume at port PM
goes down.
PC400LC-7L
10-45
HYDRAULIC SYSTEM
VALVE
1.
6-spool valve
2.
Cover 1
3.
Cover 2
4.
5.
6.
7.
8.
9.
Outline
This control valve consists of a 7-spool valve (6 spool valve + boom arm
Hi valve). A merge-divider valve, back-pressure valve, boom hydraulic
drift prevention valve, quick return valve, and Hi valve check valve are
installed to it.
Since all the valves are assembled together with connecting bolts and their
passes are connected to each other inside the assembly, the assembly is
small in size and easy to maintain.
Since one spool of this control valve is used for one work equipment unit,
its structure is simple.
A1
P11
A2
P12
A3
BP1
A4
: To swing motor
PB5
A5
PLS1
A6
PLS2
A-1
PP1
A-2
: To attachment
PP2
B1
PPS1
B3
PPS2
B4
: To swing motor
PR
B5
PS
B6
PST
B-1
PX1
P1
PX2
P2
SA
P3
SB
P4
: To tank
P5
T1
: To tank
P6
TS
: To tank
P7
TSW
: To swing motor
P8
P9
P10
10-46
PC400LC-7L
HYDRAULIC SYSTEM
12
7-SPOOL VALVE
(1/9)
PC400LC-7L
10-47
HYDRAULIC SYSTEM
12
(2/9)
Item
10-48
Torque Nm
Torque lbf ft
1. Bolt
33.3 - 43.1
24.5 - 31.7
2. Bolt
156.9 - 176.5
115.7 - 130.1
3. Bolt
65.7 - 85.3
48.4 - 62.9
4. Bolt
58.8 - 73.6
43.3 - 54.2
PC400LC-7L
HYDRAULIC SYSTEM
12
(3/9)
1. Unload valve
PC400LC-7L
10-49
HYDRAULIC SYSTEM
12
(4/9)
1. Spool (Arm)
6. Spool (Bucket)
3. Spool (Swing)
4. Spool (Boom)
9. Unload valve
Unit: mm
No.
11
Criteria
Check item
Remedy
Standard size
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
54.2 x 34.8
51.2
416.5 N
{42.5 kg}
---
333.2 N
{34 kg}
12
54.6 x 34.8
51.2
429.9 N
{42.9 kg}
---
336.1 N
{34.3 kg}
13
54.5 x 34.8
51.2
393 N
{40.1 kg}
---
314.6 N
{32.1 kg}
14
54.9 x 24.2
51.2
251 N
{25.1 kg}
---
201.0 N
{20.5 kg}
15
57.2 x 32.8
51
416 N
{42.5 kg}
---
333.2 N
{34.0 kg}
10-50
If damaged or
deformed, replace
spring
PC400LC-7L
HYDRAULIC SYSTEM
12
(5/9)
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
17
PC400LC-7L
Repair limit
Free length
x OD
Installed
length
Installed
load
Free
length
Installed
load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
---
1.2 N
{0.12 kg}
If damaged or
deformed, replace
spring
10-51
HYDRAULIC SYSTEM
12
(6/9)
1. Unload valve
5. Safety-suction valve
6. Spool
13. Spool
8. LS shuttle valve
10-52
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Free length x OD Installed length
18
19
20
Repair limit
Installed load
31.5 x 10.3
19.5
6.2 N
{0.6 kg}
---
4.9 N
{0.5 kg}
36.9 x 11.1
28
29.4 N
{3 kg}
---
23.5 N
{2.4 kg}
36.9 x 11.1
28
29.4 N
{3 kg}
---
23.5 N
{2.4 kg}
Item
PC400LC-7L
Torque Nm
Torque lbf ft
21. Valve
147.1 - 186.3
108.4 - 137.4
22. Valve
137.0 - 157.0
101.0 - 115.7
23. Valve
49.0 - 58.8
36.1 - 43.3
24. Valve
372.7 - 411.9
274.8 - 303.8
If damaged or
deformed,
replacespring
10-53
HYDRAULIC SYSTEM
12
(7/9)
1. Spool
5. Suction valve
6. Spool
3. LS select valve
16. Spool
9. LS shuttle valve
10-54
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
21
Repair limit
Installed load
31.5 x 10.3
19.5
6.2 N
{0.6 kg}
---
4.9 N
{0.5 kg}
22
48.1 x 10.8
28
17.5 N
{1.8 kg}
---
14.0 N
{1.4 kg}
23
36.9 x 11.1
28
29.4 N
{3 kg}
---
23.5 N
{2.4 kg}
24
30.7 x 20.5
23
50.0 N
{5.1 kg}
---
40.0 N
{4.1 kg}
Item
PC400LC-7L
Torque Nm
Torque lbf ft
25. Valve
372.7 - 411.9
274.8 - 303.8
26. Valve
107.9 - 147.1
79.5 - 108.4
27. Valve
323 - 402
238.2 - 296.5
28. Valve
196 - 240
144.5 - 177.0
29. Valve
147.1 - 186.3
108.4 - 137.4
30. Valve
137.3 - 156.9
101.2 - 115.7
If damaged or
deformed,
replace spring
10-55
HYDRAULIC SYSTEM
12
(8/9)
1. Safety-suction valve
7. Boom Hi spool
2. Spool
4. LS shuttle valve
6. Safety-suction valve
10-56
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
14
15
Free length x OD
Installed length
Installed load
48.1 x 10.8
28
17.5 N
{1.8 kg}
---
14.0 N
{1.4 kg}
36.9 x 11.1
28
29.4 N
{3 kg}
---
23.5 N
{2.4 kg}
Item
PC400LC-7L
Repair limit
Free length Installed load
Torque Nm
Torque lbf ft
16. Valve
372.7 - 411.9
274.8 - 303.8
17. Valve
176.6 - 196.2
130.2 - 144.7
18. Valve
137.3 - 156.9
101.2 - 115.7
If damaged or
deformed,
replace spring
10-57
HYDRAULIC SYSTEM
12
(9/9)
1. Unload valve
9. LS bypass plug
10. Screw
11. Poppet
4. Return spring
6. Return spring
16. Ball
10-58
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
17
Repair limit
Free length x OD
Installed length
Installed load
Free length
Installed load
11.5 x 4.6
8.5
1.5 N
{0.15 kg}
1.2 N
{0.12 kg}
18
46.6 x 21.8
3.3
156.8 N
{16.0 kg}
125.5 N
{12.8 kg}
19
64.5 x 32.3
63
177.5 N
{18.1 kg}
142.0 N
{14.5 kg}
20
70.9 x 18.0
59
199.8 N
{20.4 kg}
160.0 N
{16.3 kg}
Item
PC400LC-7L
Torque Nm
If damaged or
deformed,
replace spring
Torque lbf ft
21. Plug
67.5 - 85.3
49.7 - 62.9
22. Valve
147.1 - 186.3
108.4 - 137.4
23. Valve
49 - 58.8
36.1 - 32.5
24. Valve
34.3 - 44.1
25.2 - 32.5
25. Valve
147.1 - 186.3
108.4 - 137.4
26. Valve
66 - 82
48.6 - 60.4
27. Valve
19.6 - 27.5
14.4 - 20.2
10-59
HYDRAULIC SYSTEM
RELIEF VALVE
1. Spring
2. Poppet
Function
The relief valve set pressure is set to 2 stages. When power is needed, pilot pressure P is turned ON and the pressure is set
to high pressure.
Operation
The relief valve set pressure is determined by the installed load of spring (1). (First stage)
It is unnecessary to set the first and second stage individually. The second stage is set when the first stage is set.
1.
2.
10-60
PC400LC-7L
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-61
HYDRAULIC SYSTEM
Features
CLSS stands for Closed Center Load Sensing System, and has the following features.
A. Fine control not influenced by load.
B. Control enabling digging even with fine control.
C. Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
D. Energy saving using variable pump control.
Structure
The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment.
The main pump body consists of the pump itself, the PC valve and LS valve.
10-62
PC400LC-7L
HYDRAULIC SYSTEM
12
Basic principle
1.
PC400LC-7L
10-63
HYDRAULIC SYSTEM
12
2. Pressure compensation
A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
When two actuators are operated together, this valve acts to make pressure difference P between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure).
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of opening S1 and S2 of
each valve.
10-64
PC400LC-7L
HYDRAULIC SYSTEM
Function
This value reduces the discharge pressure of the main pump and supplies it as control pressure for the solenoid valves,
PPC valves, etc.
Operation
1.
PC400LC-7L
10-65
HYDRAULIC SYSTEM
12
2. When in neutral or load pressure P2 is low
(When boom is lowered and arm is in IN position and they are
moving down under own weight)
Remark
When load pressure A2 is lower than self pressure
reducing valve output pressure PR.
Valve (7) receives the force of spring (8) and PR pressure
(which is 0 MPa {0 kg/cm2} when the engine is stopped) in the
direction to close the circuit between ports P2 and A2. If the
hydraulic oil flows in port P2, the fdx P2 pressure becomes
equal to the total of the force of spring (8) and the value of area
of d PR pressure, then the area of the pass between ports P2
and A2 is so adjusted that the P2 pressure will be kept constant
above the PR pressure.
If the PR pressure rises above the set level, puppet (11) opens
and the hydraulic oil flows from the PR port through orifice a
in spool (14) and open part of poppet (11) to seal drain port TS.
Accordingly, differential pressure is generated between before
and after orifice a in spool (14) and then spool (14) moves to
close the pass between port P2 and PR. The P2 pressure is
controlled constant (at the set pressure) by the area of the oil
pass at this time and supplied as the PR pressure.
3.
10-66
PC400LC-7L
HYDRAULIC SYSTEM
12
4. When abnormal high pressure is generated
If the PR pressure on the self-pressure reducing valve rises
abnormally high, ball (16) separates from the seat against the
force of spring (15) and the hydraulic oil flows from output port
PR to TS.
Accordingly, the PR pressure lowers. By this operation, the
hydraulic devices (PPC valves, solenoid valves, etc.) are
protected from abnormal pressure.
PC400LC-7L
10-67
HYDRAULIC SYSTEM
MOTOR
KMF230ABE-5
: To tank
MA
MB
10-68
PC400LC-7L
HYDRAULIC SYSTEM
12
Specifications
Model
KMF230ABE-5
Theoretical displacement
229.4 cm3/rev
2
285+0.5
0 kg/cm
(396.8 +7.1
0 psi)
Rated revolving
speed
1,413 rpm
Brake release
pressure
Torque Nm
Torque lbf ft
1.
Bolt
27 - 34
19.9 - 25.0
2.
Bolt
98.1 - 122.6
72.3 - 90.4
PC400LC-7L
10-69
HYDRAULIC SYSTEM
12
1. Brake spring
8. Housing
2. Drive shaft
9. Piston
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
10-70
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
18
19
Repair limit
Installed
length
Installed
load
Free length
Installed load
66.5 x 25.6
45
6.96 N
{0.71 kg}
5.59 N
{0.57 kg}
---
24.5 x 11.6
14.5
7.45 N
{0.76 kg}
5.98 N
{0.61 kg}
---
Free length x OD
Torque Nm
Torque lbf ft
20. Valve
294 - 392
216.8 - 289.1
21. Valve
490.5 - 608.2
361.7 - 448.5
22. Valve
176.5 - 215.8
130.1 - 159.1
PC400LC-7L
If damaged or
deformed, replace
spring
10-71
HYDRAULIC SYSTEM
VALVE
1.
Outline
The relief portion consists of check valves (2) and (3), shuttle valves
(4) and (5), and relief valve (1).
2.
Function
When the swing is stopped, the outlet port circuit of the motor from
the control valve is closed, but the motor continues to rotate under
inertia, so the pressure at the output side of the motor becomes
abnormally high, and this may damage the motor.
To prevent this, the abnormal high pressure oil is relieved to port S
from the outlet port of the motor (high-pressure side) to prevent any
damage.
3.
Operation
A. When starting swing
When the swing control lever is operated to swing right, the
pressure oil from the pump passes through the control valve and
is supplied to port MA. As a result, the pressure at port MA
rises, the starting torque is generated in the motor, and the motor
starts to rotate. The oil from the outlet port of the motor passes
from port MA through the control valve and returns to the tank.
(Fig. 1)
B. When stopping swing
When the swing control lever is returned to neutral, the
supply of pressure oil from the pump to port MA is stopped.
With the oil from the outlet port of the motor, the return
circuit to the tank is closed by the control valve, so the
pressure at port MB rises. As a result, rotation resistance is
generated in the motor, so the braking effect starts.
If the pressure at port MB becomes higher than the pressure
at port MA, it pushes shuttle valve A (4) and chamber C
becomes the same pressure as port MB. The oil pressure
rises further until it reaches the set pressure of relief valve
(1).
As a result, a high braking torque acts on the motor and
stops the motor. (Fig.2)
When relief valve (1) is being actuated, the relief oil and oil
from port S passes through check valve B (3) and is
supplied to port MA. This prevents cavitation at port MA.
10-72
PC400LC-7L
HYDRAULIC SYSTEM
12
C. Operation of swing lock
i.
ii.
PC400LC-7L
10-73
HYDRAULIC SYSTEM
PREVENTION VALVE
Outline diagram
Explanation of effect
10-74
PC400LC-7L
HYDRAULIC SYSTEM
12
Outline
This valve reduces the swing back generated in the swing body by the
inertia of the swing body, the backlash and rigidity of the machinery
system, and the compression of the hydraulic oil when the swing is
stopped. This is effective in preventing spillage of the load and reducing
the cycle time when stopping the swing (the positioning ability is good
and it is possible to move swiftly to the next job.
Operation
1.
2.
PC400LC-7L
10-75
HYDRAULIC SYSTEM
SWIVEL JOINT
1. Cover
A1
T2
: To tank
2. Body
A2
T1
3. Slipper seal
C1
D2
4. O-ring
B2
B1
5. Shaft
D1
C2
Unit: mm
No.
6
Check item
Clearance between rotor and shaft
10-76
Criteria
Remedy
Standard Size
Standard clearance
Repair limit
80
---
---
PC400LC-7L
HYDRAULIC SYSTEM
MOTOR
KMV280ADT
Item
Specifications
Model:
Theoretical delivery
KMV200ADT
Min 130 cm3/rpm
Max 200 cm3/rpm
Torque Nm
Torque lbf ft
1. Bolt
490 - 608
361.4 - 448.4
2. Valve
294 - 343
216.8 - 252.9
PC400LC-7L
10-77
HYDRAULIC SYSTEM
12
1. Output shaft
8. Regulator piston
2. Motor case
9. Plate
3. Piston
10. Disc
17. Spring
4. Cylinder
5. Valve plate
6. End cover
10-78
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Criteria
Standard size
21
22
23
Freelength x OD
Remedy
Repair limit
Installed load
62.52 x 32.0
42.0
426.6N
{43.5 kg}
62.5 x 20.0
39.0
3.04 N
{0.31 kg}
2.45 N
{0.25 kg}
55.0x 9.0
50.0
98.1 N
{10 kg}
78.5 N
{8 kg}
Torque Nm
Torque lbf ft
24. Valve
24.5 - 34.3
18.0 - 25.2
25. Valve
65.7 - 82.4
49.7 - 60.7
26. Valve
19.6 - 27.5
14.4 - 20.2
27. Bolt
147.1 - 186.3
108.4 - 137.4
28. Valve
373 - 466
275.1 - 343.7
29. Valve
324 - 402
238.9 - 296.5
PC400LC-7L
341.3 N
{32.2 kg}
Replace
spring if dam
aged or
deformed
10-79
HYDRAULIC SYSTEM
12
1. Operation of motor
A. At low speed (motor swash plate angle at maximum)
10-80
The solenoid valve is de-energized, so the pilot pressure oil from the main pump does not flow to port P.
For this reason, regulator valve (16) is pushed down by spring (17).
The main pressure oil from the control valve pushes check valve (20), goes to end cover (6), in regulator valve
(16) and acts also on chamber b.
When this happens, the propulsion force of regulator piston (8) acts in a downward direction.
As a result, valve plate (5) and cylinder block (4) move in the maximum swash plate angle direction, the motor
capacity becomes maximum, and the system is set to low speed.
PC400LC-7L
HYDRAULIC SYSTEM
12
B. At high speed (motor swash plate angle at minimum)
When the solenoid valve is energized, the pilot pressure oil from the main pump flows to port P, and pushes
regulator valve (16) up.
As a result, the oil in chamber b is drained inside the case, and acts on chamber a via regulator valve (16).
Because of this, the propulsion force of the pressure oil at chamber a of regulator piston (8) acts in a upward
direction.
As a result, valve plate (5) and cylinder block (4) move in the minimum swash plate angle direction, the motor
capacity becomes minimum, and the system is set to high travel speed.
PC400LC-7L
10-81
HYDRAULIC SYSTEM
BRAKE
Operation
When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (13), opens
the circuit to the parking brake, and flows into chamber e of brake piston (19). It overcomes the force of spring (18),
and pushes piston (19) to the right.
When this happens, the force pushing plate (9) and disc (10) together is lost, so plate (9) and disc (10) separate and
the brake is released.
10-82
PC400LC-7L
HYDRAULIC SYSTEM
12
2. When stopping travel
Operation
When the travel lever is placed in neutral, counterbalance valve spool (13) returns to the neutral position and the
circuit to the parking brake is closed.
The pressurized oil in chamber e of brake piston (19) passes through the throttle of slow return valve (7) until spool
(13) of the counterbalance valve returns to neutral.
When spool (13) of the counterbalance valve returns to the neutral position, the oil is drained inside the case from the
throttle f of brake piston (19) and brake piston (19) is pushed fully to the left by spring (18).
As a result, plate (9) and disc (10) are pushed together, and the brake is applied.
A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (7) when the brake
piston returns, and this ensures that the brake is applied after the machine stops.
PC400LC-7L
10-83
HYDRAULIC SYSTEM
12
3. Operation of brake valve
The brake valve consists of a check valve (1), counterbalance valve
(2), and safety valve (3) in a circuit as shown in the diagram on the
right.
The function and operation of each component is as given below.
A. Counterbalance valve, check valve
Function
When traveling downhill, the weight of the machine makes it try
to travel faster than the speed of the motor.
As a result, if the machine travels with the engine at low speed,
the motor will rotate without load and the machine will run
away, which is extremely dangerous.
To prevent this, these valves act to make the machine travel
according to the engine speed (pump discharge amount).
i.
10-84
PC400LC-7L
HYDRAULIC SYSTEM
ii.
PC400LC-7L
10-85
HYDRAULIC SYSTEM
ii.
10-86
When stopping:
Low-pressure setting
27.5 kg/cm2 (0.0391 psi)
PC400LC-7L
HYDRAULIC SYSTEM
12
iii. When pressure in chamber MA has become high (when
rotating counterclockwise)
When the travel is stopped (or when traveling downhill),
chamber MA in the outlet port circuit is closed by the check
valve of the counterbalance valve, but the pressure at the
outlet port rises because of inertia.
PC400LC-7L
10-87
HYDRAULIC SYSTEM
JUNCTION VALVE
Function
This valve connects both travel circuits to each other so that the hydraulic oil will be supplied evenly to both travel motors
and the machine will travel straight.
When the machine is steered, outside pilot pressure PST closes the travel junction valve to secure high steering
performance.
Operation
When pilot pressure is turned ON
If the pilot pressure from the travel junction solenoid valve becomes higher than the force of spring (14), travel junction
spool (13) moves to the left stroke end and the junction circuit between port PTL (Left travel circuit) and PTR (Right
travel circuit) is closed.
10-88
PC400LC-7L
HYDRAULIC SYSTEM
12
When pilot pressure is turned OFF
If pilot pressure PST from the solenoid valve is 0, travel junction spool (13) is pressed by the force of spring (14) against
the right side and the pass between ports PTL and PTR is open.
If the oil flow rates in both travel motors become different from each other, the oil flows through the route between port
PTL, travel junction spool (13), and port PTR so that the oil flow rates will be equalized again.
PC400LC-7L
10-89
HYDRAULIC SYSTEM
VALVE
Lever positions
1. Travel PPC valve
8. Solenoid valve
(1) Hold
9. Accumulator
3. Service pedal
(11) Neutral
(6) Hold
(7) Arm IN
(8) Arm OUT
10-90
PC400LC-7L
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-91
HYDRAULIC SYSTEM
Function
If boom RAISE or arm IN are operated when the machine is traveling, the stroke of the spools for the boom and arm is
controlled by the travel PPC pressure and this limits the flow of oil to the boom and arm cylinders.
When the boom and arm stroke is controlled, the travel PPC pressure passes through the circuit inside the control valve to
actuate the system.
Operation
1.
10-92
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-93
HYDRAULIC SYSTEM
12
2. When travel is operated
When the travel lever is operated to right REVERSE (or FORWARD), the right (REVESE (or FORWARD) PPC
pressure pushes spool (7) to the left (or right).
Spool (7) pushes piston (3), orifice (5) closes, and stroke limit signal chamber a is shut off from the drain circuit of
the travel PPC valve.
At the same time, the right REVERSE (or FORWARD) PPC pressure passes through orifice (6) in piston (4), acts on
the right end face of piston (8), and pushes piston (8) to the left.
If arm IN is operated, spool (1) moves to the right, but the maximum stroke of the spool is limited by the amount of
movement st2 of piston (8) and becomes st1.
If boom RAISE is operated, spool (9) tries to move to the left, but the travel PPC pressure enters stroke control signal
chamber b, so the spool does not move.
10-94
PC400LC-7L
HYDRAULIC SYSTEM
12
P1
: To tank
P2
P3
P4
PC400LC-7L
10-95
HYDRAULIC SYSTEM
12
1. Spool
7. Joint
2. Metering spring
8. Plate
3. Centering spring
9. Retainer
4. Piston
10. Body
5. Disc
11. Filter
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12
Centering spring
(For P3 and P4)
Repair limit
Installed load
Free length
42.4 x 15.5
34
---
13
Centering spring
(For P1 and P2)
44.4 x 15.5
34
29.4 N
{3.0 kg}
---
14
Metering spring
26.5 x 8.2
24.9
16.7 N
{1.7 kg}
---
10-96
Installed load
13.7 N {1.4 kg} If damaged or
deformed,
23.5 N
replace spring
{2.4 kg}
13.7 N
{1.4 kg}
PC400LC-7L
HYDRAULIC SYSTEM
12
Torque Nm
Torque lbf ft
15. Bolt
11.8 - 14.7
8.7 - 10.8
16. Nut
69 - 88
50.8 - 64.9
17. Joint
34 - 44
25.0 - 32.4
18. Nut
39 - 49
28.7 - 36.1
19. Plug
6 - 11
4.4 - 8.1
20. Plug
4-9
2.9 - 6.6
PC400LC-7L
10-97
HYDRAULIC SYSTEM
12
Operation
1.
At neutral
Ports A and B of the control valve and ports P1 and P2 of the PPC
valve are connected to drain chamber D through fine control hole f in
spool (1)
2.
10-98
PC400LC-7L
HYDRAULIC SYSTEM
12
3. During fine control (when control lever is returned)
When disc (5) starts to be returned, spool (1) is pushed up by the
force of centering spring (3) and the pressure at port P1.
When this happens, fine control hole f is connected to drain chamber
D and the pressure oil at port P1 is released.
If the pressure at port P1 drops too far, spool (1) is pushed down by
metering spring (2), and fine control hole f is shut off from drain
chamber D.
At almost the same time, it is connected to pump pressure chamber
PP, and the pump pressure is supplied until the pressure at port P1
recovers to a pressure that corresponds to the lever position.
When the spool of the control valve returns, oil in drain chamber D
flows in from fine control hole f in the valve on the side that is not
working. The oil passes through port P2 and enters chamber B to fill
the chamber with oil.
4.
At full stroke
When disc (5) pushes down piston (4), and retainer (9) pushes down
spool (1), fine control hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main pump passes through
fine control hole f and flows to chamber A from port P1, and pushes
the control valve spool.
The oil returning from chamber B passes from port P2 through fine
control hole f and flows to drain chamber D.
PC400LC-7L
10-99
10-100
HYDRAULIC SYSTEM
PPC VALVE
P3 : Right reverse
: To tank
P4 : Right forward
P1
: Left reverse
P5 : Travel signal
P2
: Left forward
P6 : Steering signal
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
1. Plate
6. Centering spring
2. Body
7. Valve
3. Piston
8. Damper
4. Collar
9. Steering signal
5. Metering spring
10-101
HYDRAULIC SYSTEM
12
No.
Check item
Criteria
Installed length
Installed load
26.5 x 8.15
24.7
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
86.3 N
{8.8 kg}
7.1 N
{0.72 kg}
Metering spring
Centering spring
48.1 x 15.5
32.5
108 N
{11 kg}
12.8 x 7.3
8.5
8.8 N
{0.9 kg}
10-102
Remedy
Free length x OD
PC400LC-7L
HYDRAULIC SYSTEM
12
Torque Nm
Torque lbf ft
4.
Bolt
28 3
20.6 2.2
5.
Bolt
23.5 3.9
17.3 2.8
6.
Bolt
30.9 2.5
22.7 2.5
7.
Plug
29.4 4.9
21.6 3.6
PC400LC-7L
10-103
HYDRAULIC SYSTEM
12
Travel signal/Steering function
Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the travel signal.
Accordingly, if the machine is traveling is judged by the signal of port P5.
Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher one of the
PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neutral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1.
While in NEUTRAL
The signals of the output ports (P1 P4), travel signal (Port P5), and steering signal (Port P6) are not output.
10-104
PC400LC-7L
HYDRAULIC SYSTEM
12
2. While travelling straight
(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also operating
for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right spring chamber (I) of
steering signal valve (J) are set high. Accordingly, the steering signal valve is kept in neutral and the steering signal (Port
P6) is not output.
PC400LC-7L
10-105
HYDRAULIC SYSTEM
12
3. When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the difference of the
pilot pressure between both sides is higher than a certain level), the pilot pressure is output as the steering signal.
In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2. The pressure
in right spring chamber (l) is P4.
If (P4 P2) (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow and the higher
one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the steering signal to port P6.
10-106
PC400LC-7L
HYDRAULIC SYSTEM
12
4. When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is operating for
forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of steering signal valve (j) is
set high. Accordingly, the steering signal valve moves to the left and outputs the steering signal (port P6).
PC400LC-7L
10-107
HYDRAULIC SYSTEM
PPC VALVE
Refer to the section WORK EQUIPMENT SWING PPC VALVE for function of this valve.
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
9
10
Centering spring
Metering spring
11. Bolt
10-108
Repair limit
Installed load
33.9 x 15.3
28.4
124.5 N
{12.7 kg}
---
100 N
{10.2 kg}
22.7 x 8.1
22
16.7 N
{1.7 kg}
---
13.7 N
{1.4 kg}
Torque Nm
Torque lbf ft
13.2 1.4
9.7 1.0
If damaged or
deformed, replace
spring
PC400LC-7L
HYDRAULIC SYSTEM
VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves.
A5 : To swing motor
PC400LC-7L
: To tank
A8
P1
10-109
HYDRAULIC SYSTEM
12
Operation
WHEN SOLENOID IS TURNED OFF
Since the signal current does not flow from the controller, solenoid
(3) is turned off.
Accordingly, spool (4) is pressed by spring (6) against the left side.
By this operation, the pass from P to A is closed and the hydraulic oil
from the main pump does not flow into the actuator.
At this time, the oil from the actuator is drained through ports A and
T into the tank.
The signal current flows from the controller to solenoid (3), and the
latter is turned on.
Accordingly, spool (4) is pressed against to the right side.
By this operation, the hydraulic oil from the main pump flows
through port P and spool (4) to port A, then flows into the actuator.
At this time, port T is closed and the oil does not flow into the tank.
10-110
PC400LC-7L
HYDRAULIC SYSTEM
ACCUMULATOR
PC400LC-7L
10-111
HYDRAULIC SYSTEM
OIL FILTER
FOR BREAKER
Specifications
10-112
1. Drain plug
Rated pressure
2. Element
Flow
3. Case
4. Head cover
: 6 m
5. Relief valve
Filtering area
PC400LC-7L
HYDRAULIC SYSTEM
12
MEMORANDUM
PC400LC-7L
10-113
HYDRAULIC SYSTEM
Function
When the boom lever is not being operated, these valves act to prevent the oil at the boom bottom from leaking from spool
(1) and prevent the boom from moving down.
Operation
1.
Boom RAISE
When the boom RAISE is operated, the main pressure oil acts in the left direction on ring shaped area A
(= Area of d1 Area of d2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2.
When it overcomes the force of spring (4), poppet (5) moves to the left.
In addition, the main pressure oil acts in the right direction on seat diameter d3 of valve (6). When it overcomes the force
of spring (4), valve (6) moves to the right.
As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom
end of the boom cylinder.
10-114
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-115
HYDRAULIC SYSTEM
12
2. Boom at HOLD
When the boom is raised and the control lever is returned to the HOLD position, the oil that has flowed into the inside
of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold pressure at
the bottom of the boom cylinder are shut off.
At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring-shaped
area A (= Area of d1 Area of d2) because of the difference in the outside diameter d1 of poppet (5) and seat
diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and
hold pressure at the bottom of the boom cylinder are shut off.
In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of
valve (6).
Valve (6) is closed by the total of this force and the force of spring (4), so the main pressure oil and hold pressure at
the bottom of the boom cylinder are shut off. As a result, the boom is held in position.
10-116
PC400LC-7L
HYDRAULIC SYSTEM
12
PC400LC-7L
10-117
HYDRAULIC SYSTEM
12
3. Boom LOWER
When boom LOWER is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil
chamber b inside the poppet is drained through orifice c.
The oil at the bottom end of the boom flows from orifice a to chamber b to orifice c to drain, so the oil pressure in
chamber b drops.
When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port B
goes to port A and flows to the control valve.
10-118
PC400LC-7L
HYDRAULIC SYSTEM
When the arm lever is not being operated, these valves act to prevent the oil at the arm head from leaking from spool (1)
and prevent the arm from moving down.
Operation
1.
Arm DUMP
When the arm DUMP is operated, the main pressure oil acts in the left direction on ring shaped area A
(= Area of d1 Area of d2) because of the difference in the outside diameter d1 of poppet (5) and seat diameter d2.
When it overcomes the force of spring (4), poppet (5) moves to the left.
As a result, the main pressure oil prom the control valve passes through the opening of poppet (5) and flows to the bottom
end of the boom cylinder.
PC400LC-7L
10-119
HYDRAULIC SYSTEM
12
2. Arm at HOLD
When the arm DUMP is operated and the control lever is returned to the HOLD position, the oil that has flowed into
the inside of poppet (5) through orifice a in poppet (5) is closed by pilot piston (2). The main pressure oil and hold
pressure at the head of the arm cylinder are shut off.
At the same time, the hold pressure at the bottom end of the boom cylinder acts in the right direction on ring shaped
area A (= Area of d1 Area of d2) because of the difference in the outside diameter d1 of poppet (5) and seat
diameter d2. Poppet (5) is closed by the total of this force and the force of spring (4), so the main pressure oil and
hold pressure at the head of the arm cylinder are shut off.
In addition, the hold pressure at the bottom of the boom cylinder acts in the left direction on outside diameter d4 of
valve (6).
As a result, the arm is held in position.
10-120
PC400LC-7L
HYDRAULIC SYSTEM
12
3. Arm IN
When arm IN is operated, the pilot pressure from the PPC valve pushes pilot spool (2), and the pressure oil chamber
b inside the poppet is drained through orifice c.
The oil at the head end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in
chamber b drops.
When the pressure in chamber b drops below the pressure at port b, poppet (4) opens, and the pressure oil from port
B goes to port A and flows to the control valve.
PC400LC-7L
10-121
HYDRAULIC SYSTEM
12
4. When abnormally high pressure is generated
If abnormally high pressure is generated in the boom cylinder bottom circuit, the hydraulic oil in port B pushes check
valve (6) open, then safety valve (3) operates.
If the hydraulic drift prevention valve for the arm cylinder head circuit is installed (optional), the hydraulic oil in the
boom cylinder bottom circuit or that in the arm cylinder head circuit, having higher pressure, pushes check valve (6)
open, then safety valve (3) operates.
10-122
PC400LC-7L
HYDRAULIC SYSTEM
RETURN VALVE
Function
When arm OUT is operated, this valve reduces the pressure loss of the large amount of oil returning from the cylinder bottom.
Operation
1.
Arm at OUT
When arm OUT is operated, the pilot pressure from the PPC valve pushes pilot spool (1), and the pressure oil from
chamber b inside the poppet is drained through orifice c.
The oil at the bottom end of the arm flows from orifice a to chamber b to orifice c to drain, so the oil pressure in chamber
b drops.
When the pressure in chamber b drops below the pressure at port A, the pressure at port A and acts on ring shaped area C
(= Area of d1 Area of d2) because of the difference in the outside diameter d1 of valve (2) and seat diameter d2.
Valve (2) moves to the left and the pressure oil from port A goes to port B. From port B, the oil is drained directly to the
tank.
PC400LC-7L
10-123
HYDRAULIC SYSTEM
12
2. Arm at HOLD
The oil that has flowed through orifice a in valve (2) is closed by pilot piston (1). At the same time, the hold pressure at
the bottom end of the arm acts in the right direction on ring-shaped area C (= Area of d1 Area of d2) because of the
difference in the outside diameter d1 of valve (2) and seat diameter d2. Valve (2) is closed by the total of this force and the
force of spring (3), so port A and port B are shut off.
10-124
PC400LC-7L
HYDRAULIC SYSTEM
CHECK VALVE
Function
This valve applies back pressure to the drain circuit to prevent generation
of negative pressure on the hydraulic devices for the work equipment
(motors, cylinders, etc.)
Operation
1.
2.
PC400LC-7L
10-125
HYDRAULIC SYSTEM
1. Spool
2. Spring
ATT
:To attachment
ACC
:To accumulator
P1
TS
Unit: mm
No.
Check item
Criteria
Standard size
4.
10-126
Bolt
Remedy
Repair limit
Free length x OD
Installed length
Installed load
132.0 x 29
114.5
833 N
{85.0 kg}
spring if any
Free length Installed load Replace
damages or deformations
are found
666 N
--{68.0 kg}
Torque Nm
Torque lbf ft
59 - 74
43.5 - 54.5
PC400LC-7L
HYDRAULIC SYSTEM
12
Function
When a breaker is installed, the return oil from the breaker does not pass
through the main valve, but returns directly to the hydraulic tank. When
other attachments (crusher, etc.) are installed, the attachment and the main
valve are interconnected.
Operation
1.
2.
PC400LC-7L
10-127
HYDRAULIC SYSTEM
VALVE
1.
10-128
Bolt
CY
PI
PCY
Torque Nm
Torque lbf ft
30.9 3.4
22.7 2.5
PC400LC-7L
HYDRAULIC SYSTEM
12
1. Pilot spool
4. Safety valve
5. Check valve
6. Spring
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
7
Repair limit
Installed load
20.8 x 12.2
13.5
12.7 N
{1.3 kg}
9.8 N
{1.0 kg}
41.1 x 9.6
35
58.8 N
{6.0 kg}
---
47.0 N
{4.8 kg}
41.9 x 25.8
41
78.4 N
{8.0 kg}
---
62.7 N
{6.4 kg}
10
43.2 x 25.4
41
125.4 N
{12.8 kg}
---
100.4 N
{10.2 kg}
Torque Nm
Torque lbf ft
11. Valve
196 19.6
144.5 14.4
12. Valve
147 9.8
108.4 7.2
PC400LC-7L
If damaged of
deformed, replace
spring
10-129
HYDRAULIC SYSTEM
12
Function
If the piping between the main valve and a work equipment cylinder bursts, this valve prevents the oil from flowing back from
the work equipment cylinder to prevent sudden fall of the work equipment.
Operation
1.
2.
10-130
PC400LC-7L
HYDRAULIC SYSTEM
12
3. When oil is returned from work equipment cylinder to main valve
[When piping is normal]
The work equipment cylinder holding pressure is applied to
chamber b and check valve (5) closes.
The pilot pressure from the PPC valve is applied to port Pi. If it
is higher than the force of spring (2) (area of d), spool (1)
moves to the right standby position (1st-stage stroke).
At this time, chambers a and b are not connected to each
other.
If the pilot pressure rises higher than the force of spring (3) (area
of d), spool (1) moves further to the right and chambers a and
b connected to each other (2nd-stage stroke).
Accordingly, the oil is returned from the work equipment
cylinder to the main valve.
PC400LC-7L
10-131
HYDRAULIC SYSTEM
CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-132
PC400LC-7L
HYDRAULIC SYSTEM
12
Unit: mm
No.
Check item
Clearance
between piston
rod and bushing
Clearance
between piston
rod support pin
and bushing
Clearance
between cylinder
bottom support
pin and bushing
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
110
-0.036
-0.090
+0.261
+0.047
0.083 0.351
0.412
120
-0.036
-0.090
+0.263
+0.048
0.084 0.353
0.412
Bucket
100
-0.036
-0.090
+0.257
+0.047
0.083 0.347
0.447
Boom
110
-0.036
-0.090
+0.169
+0.100
0.136 0.259
---
Arm
110
-0.036
-0.090
+0.169
+0.100
0.136 0.259
---
Bucket
100
-0.036
-0.090
+0.187
+0.097
0.133 0.277
---
Boom
100
-0.036
-0.090
+0.190
+0.070
0.106 0.280
---
Arm
110
-0.036
-0.090
+0.195
+0.099
0.135 0.285
---
Bucket
100
-0.036
-0.090
+0.187
+0.097
0.133 0.277
---
Cylinder
Criteria
Tolerance
Boom
Arm
Standard size
Replace bushing
Replace pin or
bushing
BOOM CYLINDER
Torque Nm
Torque lbf ft
4.
530 78.5
390.9 57.9
5.
294 29.4
216.8 21.6
6.
58.9 73.6
43.5 54.2
ARM CYLINDER
4.
Bolt
Torque Nm
Torque lbf ft
892 137
657.9 101.0
5.
Piston
294 29.4
216.8 21.6
6.
Set screw
58.9 73.6
43.5 54.2
Torque Nm
Torque lbf ft
530 78.5
390.9 57.9
BUCKET CYLINDER
4.
Bolt
5.
Piston
294 29.4
216.8 21.6
6.
Set screw
58.9 73.6
43.5 54.2
PC400LC-7L
10-133
WORK EQUIPMENT
12
WORK EQUIPMENT
10-134
PC400LC-7L
WORK EQUIPMENT
12
Unit: mm
No.
Check item
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
120
-0.036
-0.090
+0.173
+0.101
0.137 0.263
1.0
120
-0.036
-0.090
+0.180
+0.112
0.148 0.270
1.0
100
-0.036
-0.090
+0.172
+0.081
0.117 0.262
1.0
100
-0.036
-0.090
+0.138
+0.077
0.113 0.228
1.0
100
-0.036
-0.090
+0.172
+0.081
0.117 0.262
1.0
100
-0.036
-0.090
+0.190
+0.097
0.133 0.280
1.0
0.5 - 1.0
2.0
PC400LC-7L
Replace
Adjust shims
10-135
10-136
WORK EQUIPMENT
ARM
PC400LC-7L
WORK EQUIPMENT
12
Unit: mm
1
-0.036
110+0.1
+0 / 0.090
129.3+1.5
0 / 126 1.2
3
4
-0.036
120+00.1/ -0.090
514.8
195
1,038
3,375
2,977.5
10
502
11
720
12
719
13
537.1
14
1,850
15
16
17
Arm as individual part
18
When press fitting bushing
19
-0.3
355+0.5
/ 351-0.8
0
-0.036
100+0.1
0 / -0.090
370
1,870
3,140
PC400LC-7L
10-137 2
10-138
WORK EQUIPMENT
OF BUCKET
PC400LC-7L
Unit: mm
1
534.1 0.5
56.3 0.5
96 1
537.1
1,839
190
---
62 1
A
140.1 8.1
130+0.063
0
100+0.1
0
10
11
371 +1
0
57
72
12
13
14
15
WORK EQUIPMENT
144
562.5+0.5
-2.5
26
165
---
16
230
17
146.1
18
137.6
19
R115
20
R85
21
410 1
22
64
PC400LC-7L
10-139
AIR CONDITIONER
12
AIR CONDITIONER
AIR CONDITIONER PIPING
A. Fresh air
2. Receiver tank
B. Recirculated air
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct
10-140
PC400LC-7L
ENGINE CONTROL
12
ENGINE CONTROL
OPERATION OF SYSTEM
STARTING ENGINE
When the starting switch is turned to the START position, the starting
signal flows to the starting motor, and the starting motor turns to start the
engine.
When this happens, the engine controller checks the signal from the fuel
control dial and sets the engine speed to the speed set by the fuel control
dial.
STOPPING ENGINE
When the engine controller detects that the starting switch is at the OFF
position, it cuts the signal to the supply pump drive solenoid to stop the
engine.
PC400LC-7L
10-141
ENGINE CONTROL
OF SYSTEM
Function
The fuel control dial is installed at the bottom of the monitor panel. A
potentiometer is installed under the knob, and when the knob is turned,
it rotates the potentiometer shaft. When the shaft rotates, the resistance
of the variable resistor inside the potentiometer changes, and the
desired throttle signal is sent to the engine controller.
The hatched area in the graph on the right is the abnormality detection
area and the engine speed is set at low idling.
10-142
PC400LC-7L
ENGINE CONTROL
CONTROLLER
PC400LC-7L
10-143
ENGINE CONTROL
Input
12 and output signals
CN1 [CN-E11]
CN2 [CN-E12]
Pin No.
Signal name
Input/Output
Pin No.
Signal name
Input/Output
CN1-1
CN2-1
GND
CN1-2
CN2-2
NC
CN1-3
Model selection 1
CN2-3
NC
Input
CN1-4
GND
CN2-4
RS232C_1RX
Input
CN1-5
NC
Input
CN2-5
NC
CN1-6
NC
Output
CN2-6
NC
CN1-7
GND
CN2-7
NC
Input
CN1-8
GND
CN2-8
NC
Input
CN1-9
NC
CN2-9
CN1-10
GND
CN2-10
Input
Input
Output
Input
CN1-11
NC
Input
CN2-11
S_NET_SHIELD GND
CN1-12
NC
Output
CN2-12
CAN_SHIELD
CN1-13
Input
CN2-13
NC
Output
CN1-14
NC
Input
CN2-14
RS232C_1TX
Output
CN1-15
Input
CN2-15
G_SHIELD (GND)
CN1-16
Memory clear
Input
CN2-16
Ne_SHIELD (GND)
CN1-17
Model selection 3
Input
CN2-17
Input
CN1-18
NC
Output
CN2-18
NC
Input
CN1-19
Input
CN2-19
CN1-20
Input
CN2-20
CN1-21
Input
CN2-21
S_NET (+)
Input/Output
CN1-22
Input
CN2-22
CAN0_L
Input/Output
CN1-23
Model selection 2
Input
CN2-23
NC
CN1-24
NC
Output
CN2-24
FWE_switch
Input
CN2-25
G pulse ()
Input
CN2-26
Ne pulse ()
Input
CN2-27
Input
CN2-28
NC
Input
CN2-29
Analog GND
CN2-30
NC
CN2-31
S_NET (+)
Input/Output
CN2-32
CAN0_H
Input/Output
CN2-33
NC
CN2-34
GND (232C_GND)
CN2-35
G pulse (+)
Input
CN2-36
Ne pulse (+)
Input
CN2-37
Input
CN2-38
NC
Input
CN2-39
Analog GND
CN2-40
10-144
Output
Input
Input
Input
PC400LC-7L
ENGINE CONTROL
12
CN3 [CN-E13]
Pin No.
Signal name
Input/Output
CN3-1
CN3-2
CN3-3
NC
CN3-4
NC
CN3-5
Injector #3 (+)
Output
CN3-6
Injector #2 (+)
Output
CN3-7
NC
Input
CN3-8
Input
CN3-9
Input
CN3-10
Output
CN3-11
Power GND
CN3-12
Output
CN3-13
Output
CN3-14
Injector #1 (+)
Output
CN3-15
Injector #3 ()
Output
CN3-16
Injector #2 ()
Output
CN3-17
NC
Input
CN3-18
Input
CN3-19
NC
CN3-20
Q command output
CN3-21
CN3-22
Supply pump 1 ()
Output
CN3-23
Supply pump 2 ()
Output
CN3-24
Injector #1 ()
Output
CN3-25
Injector #6 (+)
Output
CN3-26
Injector #4 (+)
Output
CN3-27
NC
Output
CN3-28
Input
CN3-29
NC
Input
CN3-30
GND
CN3-31
Power GND
CN3-32
Power GND
CN3-33
Injector #5 ()
Output
CN3-34
Injector #5 (+)
Output
CN3-35
Injector #6 ()
Output
CN3-36
Injector #4 ()
Output
CN3-37
NC
Output
CN3-38
Input
CN3-39
NC
Input
CN3-40
GND
PC400LC-7L
Input
Input
Output
10-145
12
10-146
PC400LC-7L
12
MEMORANDUM
PC400LC-7L
10-147
10-148
SYSTEM DIAGRAM
PC400LC-7L
12
PC400LC-7L
10-149
10-150
PC400LC-7L
12
Function
The operator can set the work mode switch on the monitor panel to
mode A, E, or B (or L) and select proper engine torque and pump
absorption torque according to the type of work.
The engine throttle and pump controller detects the speed of the
engine governor set with the fuel control dial and the actual engine
speed and controls them so that the pump will absorb all the torque at
each output point of the engine, according to the pump absorption
torque set in each mode.
: The L mode is on the multi-monitor specification machine only.
PC400LC-7L
10-151
12
1. Control method in each mode Mode A, Mode E
Matching point in mode A: Rated speed
Mode A
Mode E
If the pump load increases and the pressure rises, the engine
speed lowers.
At this time, the controller lowers the pump discharge so that the
engine speed will be near the full output point. If the pressure
lowers, the controller increases the pump discharge so that the
engine speed will be near the full output point.
By repeating these operations, the controller constantly uses the
engine near the full output point.
10-152
PC400LC-7L
12
Mode B / (Mode L)
Mode
Mode B
Mode
82%
61%
Mode B
Mode L
At this time, the controller keeps the pump absorption torque along
the constant horsepower curve and lower the engine horsepower by
the composite control of the engine and pump.
By this method, the engine is used in the low fuel consumption area.
: The L mode is on the multi-monitor specification machine only.
PC400LC-7L
10-153
12
2. Function to control pump during travel
When the travel is operated in A operation, or E or B working
mode, the working mode stays as it is, and the pump absorption
torque and engine speed rise to A travel mode.
3.
10-154
PC400LC-7L
CONTROL FUNCTION
Function
The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
PC400LC-7L
10-155
12
1. LS control function
The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the
output pressure from the LSEPC valve to the LS valve according to the operating condition of the actuator.
By this operation, the start-up time of the pump discharge is optimized and the composite operation and fine control
performance is improved.
2.
Cut-off function
When the cut-off function is turned on, the PCEPC current is
increased to near the maximum value.
By this operation, the flow rate in the relief state is lowered to
reduce fuel consumption.
Operating condition for turning on cut-off function
Condition
The average value of the front and rear pressure sensors is above
285 kg/cm2 (4053 psi) and the one-touch power maximizing
function is not turned on
The cut-off function does not work, however, while the machine is
travelling in mode A or the arm crane operation width swing lock switch
is turned on.
1.
Relief pressure
Condition
During travel
When swing lock switch is turned on
355 kg/cm2 (5049 psi)
10-156
PC400LC-7L
12
MEMORANDUM
PC400LC-7L
10-157
Function
Power can be increased for a certain time by operating the left knob switch.
When the machine push-up switch is operated, the boom pushing force is increased.
10-158
PC400LC-7L
12
1. One-touch power maximizing function
When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 7% to increase the digging force.
If the left knob switch is turned on in working mode A or E, each function is set automatically as shown below.
Working mode
Engine/Pump control
Operation time
Cancel
A, E
2.
Switch
OFF
ON
PC400LC-7L
10-159
FUNCTION
Function
If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the
medium level automatically to reduce the fuel consumption and noise.
If any lever is operated, the engine speed rises to the set level instantly.
10-160
PC400LC-7L
12
Operation
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,300 rpm)
for 4 seconds, the engine speed lowers to the second deceleration level (about 1,300 rpm) and keeps at that level until any lever
is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly
to the level set with the fuel control dial.
PC400LC-7L
10-161
PREVENTION FUNCTION
Function
After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the
engine. If the coolant temperature rises too high during work, the pump load is reduced to prevent overheating.
10-162
PC400LC-7L
12
1. Auto-warm-up function
After the engine is started, if the engine coolant temperature is low, the engine speed is automatically raised to warm the
engine.
2.
PC400LC-7L
10-163
CONTROL FUNCTION
Function
The swing lock and swing holding brake functions are installed.
10-164
PC400LC-7L
12
1. Swing lock and swing holding brake functions
The swing lock function (manual) is used to lock machine from swinging at any position. The swing holding brake
function (automatic) is used to prevent hydraulic drift after the machine stops swinging.
Swing lock switch and swing lock/holding brake
Lock switch
Lock lamp
Function
Operation
OFF
OFF
If swing lever is set in neutral, swing brake operates in about 7 sec. If swing lever is
operated, brake is released and machine can swing freely.
ON
ON
Swing lock
Swing lock operates and machine is locked from swinging. Even if swing lever is
operated, swing lock is not reset and machine does not swing.
If the controller, etc. has a problem, the swing holding brake does not work normally, and the machine cannot swing,
the swing lock can be reset with the swing holding brake release switch.
ON
(When control has trouble)
OFF
(When controller is normal)
ON
OFF
ON
OFF
Swing brake
Swing lock is
canceled
Swing lock is
turned on
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.
If the swing lock is reset, swinging is stopped by only the hydraulic brake of the safety valve. Accordingly, if
swinging is stopped on a slope, the upper structure may drift hydraulically.
2.
PC400LC-7L
10-165
CONTROL FUNCTION
Function
The pumps are controlled and the travel speed is changed manually or automatically, to secure proper travel performance
matched to the type of work and job site during travel.
10-166
PC400LC-7L
12
Pump control function during travel
If the machine travels in a work mode other than mode A, the work mode and the engine speed are kept as they are and the
pump absorption torque is increased.
For details, see ENGINE/PUMP COMPOSITE CONTROL FUNCTION.
1.
Lo (Low speed)
Hi (High speed)
90
82
100
Max.
Max.
Min.
3.2
4.5
5.5
B. Automatic change according to engine speed If the fuel control dial is used to set the engine speed to less than 1,200
rpm:
When traveling in Lo, it will not switch even when set to Hi or Mi.
When traveling in Hi or Mi, it will switch automatically to Lo.
C. Automatic changes according to pump discharge pressure
When traveling with the travel speed switch set to Hi or Mi, it the
load increases, such as when traveling uphill, and the travel
pressure goes above 330 kg/cm2 (4693 psi) for more than 0.5 sec.,
the travel motor capacity will automatically change to low speed
(equivalent to Lo). (The travel speed switch will stay at Hi or Mi.)
After continuing to travel in Lo, if the load increases, such as
when traveling on level ground or traveling downhill, and the
travel pressure goes below 190 kg/cm2 (2702 psi) for more than
0.5 sec., the travel motor capacity will automatically change and
will return to Hi or Mi.
: The Mi mode is on the multi-monitor specification machine only.
PC400LC-7L
10-167
Function
This function is available only with the ATT specification. The function acts as follows according to the flow command and
working mode from the monitor.
1.
It throttles the ATT PPC pressure and controls the flow when the pedal is fully depressed.
2. In mode B and the other modes, it switches to ATT single acting (B) or double acting (other modes).
: The ATT flow control adjustment function is on the multi-monitor specification machine only.
10-168
PC400LC-7L
COMPONENT PARTS
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
Function
The engine revolution sensor is installed to the ring gear of the engine flywheel. It electrically calculates the number of the
gear teeth which pass in front of it and transmits the result to the engine throttle and pump controller.
A magnet is used to sense the gear teeth. Each time a gear tooth passes in front of the magnet, a current is generated.
PC400LC-7L
10-169
1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:
Function
The junction block has 7 pressure switches, which check the operating condition of each actuator by the PPC pressure and
transmit it to the engine throttle and pump controller.
10-170
PC400LC-7L
PRESSURE SENSOR
1. Sensor
2. Connector
Function
The pump pressure sensor is installed to the inlet circuit of the control valve. It converts the pump discharge pressure into a
voltage and transmits it to the engine throttle and pump controller.
Operation
The oil pressure applied from the pressure intake part presses the diaphragm of the oil pressure sensor, the diaphragm is
deformed.
The gauge layer facing the diaphragm measures the deformation of the diaphragm by the change of its resistance, then
converts the change of the resistance into a voltage and transmits it to the amplifier (voltage amplifier).
The amplifier, amplifies the received voltage and transmits it to the engine throttle and pump controller.
Relationship between pressure P kg/cm2 (psi) and output voltage (V) is as follows. V = 0.08 [0.008] P + 0.5
PC400LC-7L
10-171
10-172
CONTROLLER
PC400LC-7L
12
Input and output signals
CN-1
CN-2
Pin No.
Signal name
NC
3
4
Input/ Output
Pin No.
Signal name
Input/ Output
NC
Input
NC
NC
Input
NC
232C_RxD
Input
NC
NC
NC
NC
NC
Model selection 4
NC
NC
10
Signal GND
10
NC
11
Knob SW
12
NC
13
14
NC
15
NC
16
NC
17
18
NC
19
20
NC
21
NC
22
POT_PWR
23
24
NC
PC400LC-7L
Input
Input
Input
Input
Input
Output
11
NC
12
CAN shield
13
Model selection 5
14
232C_TxD
15
NC
16
Input
17
Model selection 3
Input
18
NC
19
20
NC
21
S_NET
Input/output
Output
22
CAN0_L
Input/output
Input
23
NC
24
FWE_SW
25
NC
26
NC
27
Model selection 2
28
NC
29
30
NC
31
32
CAN0_H
33
NC
34
35
36
NC
37
Input
38
Input
39
40
Input
Input
Input
Input
Input
Output
Output
Input
Input
Input/ output
Input
Input
10-173
12
CN-3
Pin No.
Signal name
Input/Output
VB (controller power)
Input
Input
NC
LS-EPC
Output
Output
NC
NC
Input
10
Input
11
VB (controller power)
Input
12
Input
13
Input
14
KEY_SIG
Input
15
NC
16
PC-EPC
Output
17
Output
18
Output
19
Input
20
Input
21
Input
22
NC
23
Input
24
KEY_SIG
Input
25
NC
26
Output
27
Output
28
Output
29
Input
30
31
NC
Input
32
Input
33
Input
34
NC
35
NC
36
NC
37
38
NC
39
Input
40
Input
10-174
Output
Output
PC400LC-7L
MONITOR SYSTEM
12
MONITOR SYSTEM
The monitor system monitors the condition of the machine with sensors installed on various parts of the machine. It
processes and immediately displays the obtained information on the panel notifying the operator of the condition of the
machine.
The panel is roughly divided as follows.
1.
2.
Gauge section to display the condition constantly (Coolant temperature, hydraulic oil temperature, fuel level, etc.)
The monitor panel also has various mode selector switches and functions to operate the machine control system.
PC400LC-7L
10-175
MONITOR SYSTEM
12
1. Monitor panel
Outline
The monitor panel has the functions to display various items and the functions to select modes and electric parts.
The monitor panel has a CPU (Central Processing Unit) in it to process, display, and output the information.
The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches.
10-176
PC400LC-7L
MONITOR SYSTEM
Input
and output signals
12
CN-1
CN3
Pin No.
Signal name
Input/output
Pin No.
Signal name
Input/output
Key ON
Input
NC
Input
Key ON
Input
NC
Input
Output
NC
Input
Starting signal
Input
NC
Input
Input
NC
Input
GND
NC
Input
GND
VB +
RS230C CTS
Input
Input
RS230C RXD
Input
Output
RS230C RXD
Input/Output
10
Output
10
RS230C RXD
Input/Output
11
Buzzer ON signal
Input
11
BOOTSW
Input
12
Input
12
NC
Input
13
GND
14
CAN (SHIELD)
Input
15
CAN (+)
Input
16
CAN (-)
Input
CN-2
Pin No.
Signal name
Input/output
Input
Fuel level
Input
Input
Input
Input
NC
Input
Input
Input
N/W signal
Input/Output
10
N/W signal
Input/Output
11
Battery charge
Input
12
Input
13
14
Buzzer drive
Input
15
Limit SW (window)
Input
16
Buzzer cancel
Input
17
Swing lock
Input
18
Preheat
Input
19
Light switch
Input
20
N/W GND
PC400LC-7L
10-177
MONITOR SYSTEM
MONITOR PORTION
10-178
1. Wiper motor
2. Preheating monitor
8. Service monitor
PC400LC-7L
MONITOR SYSTEM
Symbol
Display item
Swing lock
Preheating
Power Max
Display method
Swing lock switch
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
Flashes
ON
ON
ON
Up to 30 sec.
ON
Flashes
OFF
Being pressed
Lights up but goes out after approx. 9 sec when kept pressed
Flashes
Engine coolant
temperature
Hydraulic
oiltemperature
Fuel level
PC400LC-7L
10-179
MONITOR SYSTEM
12
Gauge
Engine coolant
temperature (C)
10-180
Range
Temperature, volume
Indicator
Buzzer sound
A1
105
Red
A2
102
Red
A3
100
Green
A4
80
Green
A5
60
Green
A6
30
White
B1
105
Red
B2
102
Red
B3
100
Green
B4
80
Green
B5
40
Green
B6
20
White
C1
467
Green
C2
381
Green
C3
295
Green
C4
147.5
Green
C5
114
Green
C6
80.5
Red
PC400LC-7L
MONITOR SYSTEM
12
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil temperature
gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.
Symbol
Display item
---
Battery charge
---
---
---
Lights up when
abnormal
Maintenance
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.
PC400LC-7L
Color of symbol
No display
10-181
MONITOR SYSTEM
12
Display
category
Symbol
Display item
Display range
Display method
Wiper
Working mode
Travel speed
Monitor
Service meter
10-182
Auto-deceleration
ON OFF
Service meter
indicator
PC400LC-7L
MONITOR SYSTEM
12
SWITCHES
1. Selector switch
2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
PC400LC-7L
10-183
MONITOR SYSTEM
12
Display
[A]
A mode (default)
[E]
E mode
[L]
Heavy-lift mode
[B]
Selector switch
This is used when making detailed settings in each working mode. (For details, see ATTACHMENT FLOW CONTROL
FUNCTION for modes A and E.)
Maintenance switch
Check the condition of the maintenance items. (For details, see MAINTENANCE FUNCTION.)
Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically set
to ON.
Display
Setting
Crawler symbol + Lo
Crawler symbol + Mi
Medium speed
Crawler symbol + Hi
High speed
Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes
OFF INT ON OFF
Use the wiper monitor display to check the
present condition.
The relationship between the wiper setting and
the monitor display is as shown in the table on
the right.
10-184
Display
Setting
None
OFF
INT
Intermittent actuation
Wiper symbol + ON
ON
Continuous actuation
PC400LC-7L
MONITOR SYSTEM
12
Window washer switch
While the switch is being pressed, window washer liquid is sprayed out. There is a time delay before the wiper starts.
Control switch
This is used for control when using the maintenance function or select function. (For details, see each function.)
Display brightness, contrast adjustment switch Use this switch when adjusting the display brightness and contrast. (For
details, see each function.)
PC400LC-7L
10-185
MONITOR SYSTEM
MODE FUNCTION
This is used when setting the flow in each working mode. It is possible
to make the setting when genuine attachment piping is installed and
the initial value setting function on the service menu has been used to
set to ATTACHMENT INSTALLED.
It is possible to check on the working mode monitor if this function
can be set.
Working mode
Monitor display
A mode
E mode
B mode
MEHOD OF USE
Carry out the setting on the normal screen
1.
A mode, E mode
A. Press select switch (1) on the monitor to move to the adjustment
screen.
B. Press control switch (2) to select the flow level.
Control switch
Actuation
10-186
Flow level
Flow (L/min.)
Remarks
530
Default
430
370
300
230
165
100
30
PC400LC-7L
MONITOR SYSTEM
12
2. B mode
A. Press select switch (1) on the monitor to move to the screen for
selecting the 3-stage flow level.
B. Press control switch (2), or input [01] [03] with the numeral
10-key pad to choose one on the three flow levels.
No.
01
02
03
No.
Remarks
01
230
Default
02
190
03
150
Actuation
PC400LC-7L
10-187
MONITOR SYSTEM
12
F.
G. Check the set value with the working mode monitor. The
relationship between the display level and the set value is as
shown in the table on the right, and it is possible to check the
level of the flow that can be set.
10-188
Flow
level
When flow
is 300 L/
min.
200
280
360
180
260
340
160
240
320
140
220
300
120
200
280
100
180
260
80
160
240
Remarks
Default
Display level
220 or 360
200 or 340
180 or 320
160 or 300
140 or 280
120 or 260
100 or 240
80
PC400LC-7L
MONITOR SYSTEM
FUNCTION
Item
01
Engine oil
500
02
500
03
Fuel filter
500
04
Hydraulic filter
1000
05
500
06
Corrosion resistor
1000
07
1000
08
2000
09
1000
10
Hydraulic oil
5000
The above replacement intervals are set for each item, and the time remaining to maintenance is reduced as the machine is
operated. The content of the caution display differs according to the remaining time. The relationship is as shown in the
table below.
Display
Condition
None
Remaining time for maintenance for all items is more than 30 hours
There is one or more items with less than 30 hours remaining time for
maintenance
There is one or more items with less than 0 hours remaining time for
maintenance
PC400LC-7L
10-189
MONITOR SYSTEM
12
METHOD OF CHECKING STATUS
MAINTENANCE ITEMS
Operate as follows when on the operator screen.
1.
2.
Press control switch (2), or use the 10-key pad to input the number
(01 10) of the maintenance item to select the item.
The cursor moves and the item is highlighted.
The display method is the same as described on the previous page
(relationship between remaining time and caution display). If the
remaining time is less than 30 hours, the item is displayed in
yellow, and if it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
1.
2.
Use the maintenance reset screen to check the content, and if there is
any problem, press input confirmation switch (3) to move to the check
screen. If the wrong item is selected, press return switch (4) to return
to the maintenance list screen.
3.
10-190
PC400LC-7L
MONITOR SYSTEM
12
BRIGHTNESS, CONTRAST ADJUSTMENT FUNCTION
This function is used to adjust the brightness and contrast of the display.
ADJUSTMENT METHOD
Operate as follows when on the operator screen.
1.
Press display brightness/contrast adjustment switch (1) and switch to the adjustment screen.
Relationship between menu symbol and content.
No.
Symbol
Content
01
Return mark
Return
02
Contrast
03
Brightness
2.
Press control switch (2), or use the 10-key pad to input the number (00
02) to select either contrast or brightness. After completing the
selection, press input confirmation switch (3) and return to the
adjustment screen. Then press return switch (4) or use the 10-key pas
to set to [00] and press input confirmation switch (3) to return to the
normal screen.
3.
Press control switch (2) and adjust the brightness and contrast as
desired.
Control switch
Actuation
PC400LC-7L
10-191
MONITOR SYSTEM
When the starting switch is at the OFF position, press return switch (1)
and control switch (2) on the monitor at the same time, and the service
meter is shown on the display.
This display is shown only while the two switches are being pressed.
When the switches are released, the display goes out. Note that it takes
3 5 seconds after the switches are pressed for the service meter
display to appear.
10-192
PC400LC-7L
MONITOR SYSTEM
12
While the user code is being displayed, if the input confirmation
switch is pressed, the service code and failure code can be displayed.
If there is more than one service code or failure code, the display
switches every 2 seconds and displays all the service codes/failure
codes that caused the user code to be displayed. Even if service codes/
failure codes have occurred, if they did not cause the user code to be
displayed, this function does not display them.
If the telephone number has been set using the telephone number input
on the service menu, it is possible to switch on the service code/failure
code and display the telephone symbol and telephone number.
For details of inputting and setting the telephone number, see
SPECIAL FUNCTIONS OF MONITOR PANEL in the TESTING
AND ADJUSTING section.
PC400LC-7L
10-193
SENSOR
12
SENSOR
The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the
chassis ground.
Type of sensor
When normal
When abnormal
Name of sensor
Contact
ON (closed)
OFF (open)
Contact
OFF (open)
ON (closed)
Resistance
---
---
Coolant temperature
Resistance
---
---
Fuel level
Resistance
---
---
Contact type
OFF (open)
ON (closed)
10-194
PC400LC-7L
SENSOR
TEMPERATURE SENSOR
1. Thermistor
4. Tube
2. Body
5. Wire
3. Tube
6. Connector
PC400LC-7L
10-195
SENSOR
10-196
PC400LC-7L
20
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP
MANUAL.
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1.
The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2.
The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3.
These standard values are not the standards used in dealing with claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
PC400LC-7L
20-1 1
12
Item
Engine speed
Engine
Measurement condition
High idling
Low idling
Rated speed
At rated output
Valve clearance
(normal temperature)
Compression
pressure
Unit
rpm
kPa
{mmHg}
C
Bosch
index
Standard value
1,930 50
1,000 25
1,850
SAA6D125E-3
Permissible value
1,930 50
1,000 25
1,850
87 {650}
mm
Max. 700
Max. 4.0
Max. 1.0
0.33
0.71
Max. 700
6.0
2.0
-----
MPa {kg/cm2}
(rpm)
2.0 {20}
(150-200)
kPa
{mmH2O}
1.96 {200}
MPa
{kg/cm2}
0.21 {2.1}
0.18 {1.8}
0.08 {0.8}
0.07 {0.7}
90-120
120
mm
Approximately 13
Approximately 13
mm
14-16
14-16
20-2 1
PC400LC-7L
12
Item
Measurement conditions
Unit
Standard value
Permissible value
1,930 100
1,930 100
1,830 100
1,830 100
1,300 100
1,300 100
mm
9.5 0.5
9.5 0.5
mm
85 10
85 10
85 10
85 10
115 12
Max. 10
85 10
85 10
85 10
85 10
115 12
Max. 15
15.7 4.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 4.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
12.7 2.9
{1.3 0.3}
Max. 21.6
{Max. 2.2}
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
operating range
2 pumps at relief
operating range
Engine speed
operating range
oil temperature: Within
At 2-pump relief + one Hydraulic
operating range
touch power up
Engine at high idling
Arm relief + One-touch power max.
switch in ON condition
condition
condition
PC400LC-7L
rpm
Engine stopped
At center of control lever grip
Max. reading up to stroke end
operation range
operating range
At center of control lever grip
Max. reading up to stroke end
N {kg}
20-3 1
12
Category
Item
Unload pressure
Measurement conditions
Unit
Standard value
Permissible value
4.2 1.0
{42 10}
4.2 1.0
{42 10}
34.81+1.47
33.34-36.77
-0.98
(37.27+1.47 )
-0.98
RAISE
At lowpressure
setting
18.14 0.98
{185 10}
16.67-19.61
{170-200}
At highpressure
setting
31.38 1.47
{320 15}
29.2-33.34
{300-340}
34.81+1.47
33.34-36.77
Boom
Hydraulic pressure
Arm
LOWER
-10
Hydraulic oil
temperature:
Within operation
range
Engine at high
idling
(35.79-39.23)
{355+15
-10
(380+15)}
-0.98
(37.27+1.47 )
-0.98
{355+15
-10
+15
(380
MPa
{kg/cm2}
-10
)}
34.81+1.47
-0.98
{355+15
-10
(380+15)}
-10
30.89+1.47
-2.45
Swing
(37.27+1.47 )
-0.98
Bucket
(35.79-39.23)
{315+15}
- -25
37.27+2.94
(35.79-39.23)
{340-375 (365- 400)}
27.95-32.85
{285-335}
{380+30}
35.79-40.70
{365-415}
3.24 0.2
{33 2}
2.84-3.43
{29-35}
When all
control levers
in NEUTRAL
position
4.2 1.0
{42 10}
4.2 1.0
{42 10}
2.65 0.1
{27 1}
2.65 0.1
{27 1}
-0.98
Travel
-10
LS differential pressure
20-4 1
PC400LC-7L
12
Category
Item
Measurement conditions
range
Bucket: Empty
Engine at high idling
Working mode: A mode
Swing circle misalignment amount when
stopping after one turn
Unit
Standard value
Permissible value
deg.
(mm)
Max. 130
Max. 160
3.7 0.4
Max. 4.6
5.4 0.5
Max. 6.4
sec.
33.0 3.3
Max. 38
mm
90
Time taken to start
swing
sec.
operation range
Bucket: Empty
Engine at high idling
Working mode: A mode
Time required for passing points 90
180
Swing
Hydraulic drift of
swing
range
Engine stopped
Keeping upper structure transverse on slope of
15 degrees
minutes
PC400LC-7L
20-5 1
12
Category
Item
Measurement conditions
Unit
Standard value
Permissible value
L/min
Max. 5.5
Max. 11
Lo
67.3 13.5
45.0-84.5
Mi
48.1 7.2
34.0-58.0
Hi
36.7 3.6
32.0-44.0
Lo
24.0 4.8
18.9-31.0
17.1 2.6
14.4-21.0
13.1 1.3
11.7-15.1
Max. 200
Max. 300
Swing
operation range
swing relief
Travel speed
(Idle travel)
Travel
Travel speed
(Actual travel)
Travel deviation
20-6 1
sec.
Mi
sec.
Hi
mm
PC400LC-7L
12
Category
Item
Unit
Standard value
Permissible value
mm
L/min
Max. 20
Max. 40
Max. 600
Max. 900
Max. 25
Max. 38
Max. 85
Max. 128
Max. 30
Max. 45
Travel
Measurement conditions
operating range
Engine stopped
Parking machine on slope 12 degrees
with sprocket facing upslope
Sliding distance for 5 minutes
Hydraulic oil temperature: Within
Leakage of travel
motor
operating range
Work equipment
operation range
PC400LC-7L
mm
20-7 1
4.0 0.4
Max. 4.8
LOWER
2.9 0.3
Max. 3.4
CURL
4.3 0.4
Max. 5.0
3.6 0.4
Max. 4.3
3.6 0.4
Max. 4.3
2.9 0.3
Max. 3.5
Measurement conditions
Unit
RAISE
Item
DUMP
Cate
gory
CURL
12
Boom
operation range
Work equipment
Arm
operation range
sec.
Bucket
DUMP
operation range
20-8 1
PC400LC-7L
12
Category
Item
Measurement Condition
Unit
Boom
Standard value
Permissible value
Max. 3.0
Max. 3.6
Max. 3.0
Max. 3.6
Max. 3.0
Max. 5.0
4.5
20
10
50
range
Time lag
Work equipment
Arm
sec.
range
Bucket
range
Internal leackage
Cylinders
Center swivel
joint
PC400LC-7L
range
cc/min
20-9 1
12
Category
Item
Measurement Condition
Unit
Standard value
Permissible value
mm
Max. 400
Max. 440
Swerving amount in
simultaneous operation
of work equipment and
travel
Hydraulic pump
delivery
operation range
20-10 1
L/min
PC400LC-7L
12
Item
Measurement Condition
Check point
Unit
Standard value
Permissible
value
Category
As desired
P1
P2
Average pressure
(MPa {kg/cm2})
P1+P2
2
See graph
See graph
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.
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.
PC400LC-7L
20-11 1
12
MEMORANDUM
20-12 1
PC400LC-7L
12
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102
MEASURING ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
HANDLING FUEL SYSTEM DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
RELEASING RESIDUAL FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
INTAKE AIR PRESSURE (BOOST PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
FAN BELT AND ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-107
SWING CIRCLE BEARING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
CONTROL CIRCUIT - BASIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
PUMP PC CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
PUMP LS CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
SOLENOID VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
PPC VALVE - OUTPUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
SWING PPC VALVE - PLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-133
MEASURING OIL LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
BLEEDING AIR FROM EACH PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
DIODE TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
MONITOR PANEL - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-141
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . 20-167
PREPARATION WORK FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-168
PM CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170
UNDERCARRIAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
PC400LC-7L
20-101 1
SERVICE TOOLS
12
A
B
Part No.
1
Measuring exhaust gas color
D
1
E 2
3
799-101-5002
Hydraulic tester
Dial gauge
1 with magnet
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
1
1
2
2
1
1
2
2
1
1
4
4
790-261-1203
2
2
Measuring clearance of swing circle bearing
1
2
1
L
2
20-102 1
1
2
Remarks
799-201-2202
799-101-1502
799-201-1502
Commercially
available
Commercially
available
795-502-1590
795-471-1410
6217-71-6112
795-799-1170
799-201-1504
1
Measuring engine oil pressure
Part name
Qty
Testing/Adjusting item
Symbol
SERVICE TOOLS
799-401-2320
799-101-5002
790-261-1203
799-401-2320
Commercially
available
799-101-5002
790-261-1203
799-101-5220
07002-11023
799-101-5002
790-261-1203
799-101-5220
07002-11023
799-101-5002
790-261-1203
799-101-5220
07002-11023
Smoke meter
Feeler gauge
Compression gauge
Adapter
Gasket
Puller
Blow-by checker
Same as G
(Size): 10 x 1.25 mm
Same as G1
Same as K2
Same as G
PC400LC-7L
SERVICE TOOLS
Part No.
1
2
3
1
P
2
1
2
-----
---
---
---
---
799-101-5002
790-261-1203
799-101-5220
07002-11023
799-401-2701
799-101-5002
790-261-1203
799-401-3100
799-401-3200
799-101-5002
790-261-1203
970-301-1740
Commercially
available
799-627-1120
799-101-1502
79A-264-0021
79A-264-0091
Commercially
available
Commercially
available
Commercially
available
Part name
Qty
Testing/Adjusting item
Symbol
12
Remarks
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring
Differential pressure gauge
Hydraulic tester
Digital hydraulic tester
Adapter
Adapter
Hydraulic tester
Digital hydraulic tester
Joint
1
1
4
4
1
1
1
1
1
1
1
1
Measuring cylinder
Wear gauge
Digital thermometer
Push-pull scale
Push-pull scale
1
1 Same as B
1 0 - 294 N {0 - 30 kg}
1 0 - 490 N {0 - 50 kg}
Scale
Stopwatch
Tester
Same as G1
Same as M2
Same as G1
(Size): 02
(Size): 03
Same as G1
(Size): PF1/4 + PT1/4
For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor panel, controllers,
sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connectors and electric circuit diagram of
each system.
PC400LC-7L
20-103 1
12
Turn the starting switch ON and set the monitor panel to Monitoring.
For the operating method, see Special functions of monitor panel.
Monitoring code: 01002 Engine Speed
01006 Engine Speed
Code 01002 is information of the engine controller and code 01006 is information of the pump controller. The engine
speed can be measured with either of those codes.
The engine speed is displayed in rpm.
2.
Run the engine and raise the engine water temperature and hydraulic
oil temperature to the operating range.
3.
Start the engine and set the fuel control dial in the low idling
position (MIN).
ii.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
iii. While relieving the arm circuit by moving the arm in, keep pressing the one-touch power maximizing switch.
The one-touch power maximizing function is reset automatically in about 8.5 seconds even if the switch is kept
held. Accordingly, measure the engine speed in that period.
E. Measuring auto-deceleration speed
i.
Start the engine and set the fuel control dial in the high idling position (MAX).
ii.
iii. Set the work equipment control and swing control levers in neutral.
The engine speed lowers to a certain level about 5 seconds after all the levers are set in neutral. This level is the
auto-deceleration speed.
20-104 1
PC400LC-7L
ENGINE
12
ENGINE
Remark
To tune, test and troubleshoot the following procedures you must refer to the ENGINE SHOP MANUAL for the
SAA6D125E-3 series engine, Section 12, for the tool requirements and proper procedures.
FUEL
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
HANDLING FUEL SYSTEM DEVICES
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
RELEASING RESIDUAL FUEL SYSTEM PRESSURE
PC400LC-7L
20-105 1
12
Open the engine hood and remove belt protection covers (2 pieces).
2.
Press the intermediate point between alternator pulley and fan pulley
with a finger and measure deflection a of the belt.
Deflection a when pressing force is approximately 58.8 N
{approximately 6 kg}: 13 mm
ADJUSTING
If the deflection is abnormal, adjust it according to the following
procedure.
1.
2.
Turn nut (4) to move alternator (5) and adjust the belt tension.
If nut (4) is:
tightened clockwise, the belt tension is decreased.
loosened counterclockwise, the belt tension is increased.
Check breakage of the pulleys, wear of the V-grooves and V-belts,
and contact of the belts and V-grooves.
If a belt is lengthened to the adjustment limit, cut, or cracked, replace it new one.
3.
20-106 1
PC400LC-7L
12
Open the engine hood and remove belt protection covers (2 pieces).
2.
ADJUSTING
If the deflection is abnormal, adjust it according to the following
procedure.
1.
2.
3.
PC400LC-7L
20-107 1
12
Fix dial gauge J to outer race (1) or inner race (2) of the swing circle
and apply the probe to the end face of inner race (2) or outer race (1)
on the opposite side.
Set dial gauge J on the front or at rear side of the machine.
2.
Set the work equipment in the maximum reach position and set the
bucket tip at the height of the revolving frame bottom.
At this time, the front end of the upper structure lowers and the
rear end rises.
3.
4.
Set the arm at almost right angle to the ground and lower the boom
until the track shoe at the front end of the machine rises.
At this time, the front end of the upper structure rises and the rear
end lowers.
5.
6.
Return the machine to the position of step 2 and check that dial gauge
J indicates 0 again.
If dial gauge J does not indicate 0, repeat steps 3 - 5.
20-108 1
Symbol
J
Part Number
Commercially
available
Part Name
Dial gauge
PC400LC-7L
12
Run the engine at low idling and move the machine forward by the
length of track on ground and stop slowly.
2.
Place square bar [1] on the track shoe between idler (1) and 1st carrier
roller (2).
As the square bar [1], use an L-shape steel, etc. which will be
deflected less.
3.
ADJUSTING
If the track shoe tension is abnormal, adjust it according to the
following procedure.
1.
2.
PC400LC-7L
20-109 1
12
Part Number
799-101-5002
790-261-1203
799-101-5220
07002-11023
Part Name
Hydraulic tester
Digital hydraulic tester
Nipple (10x1.25 mm)
O-ring
The oil pressure in work equipment, swing, and travel circuits can be
checked with the monitoring function of the monitor panel (For the
operating method, see Special functions of monitor panel).
Monitoring code: 01100 F Pump Pressure
01101 R Pump Pressure
MEASURING
1.
Preparation work
WARNING! Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the residual
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure of the
hydraulic tank.
A. Open the pump room cover and remove oil pressure pick-up
plugs (1) and (2).
(1): Front pump discharge pressure pickup plug.
(2): Rear pump discharge pressure pickup plug.
B. Install nipple K2 and connect it to oil pressure gauge [1] of
hydraulic tester K1.
Use the oil pressure gauges of 600 kg/cm2, (8534 psi).
C. Run the engine and raise the hydraulic oil temperature to the
operating range.
20-110 1
PC400LC-7L
12
2. Combination of pump, actuator, and valve
When the oil from the pumps is divided, the front pump and rear pump act independently on each actuator. Note that
different actuators relieve different valves.
When the work equipment circuit or swing circuit is relieved singly, the oils of the pumps are merged. When the
travel circuit is relieved singly, the oils of the pumps are divided.
The actuators in the table are arranged in the order when the
control valve is seen from the front of the machine (and an
Pump
Actuator
Valve relieved
attachment is installed to the service valve).
3.
4.
B. Run the engine at high idling and relieve the cylinder and measure
the oil pressure.
The pressure measured when the main relief valve is relieved
is indicated.
If the one-touch power maximizing switch is released, the
valve is relieved at low pressure. If the former is pressed, the lower is relieved at high pressure.
If the swing lock switch is turned ON, the 2-stage relief valve is kept turned ON and the valve is relieved at high
pressure. Accordingly, keep the swing lock switch turned OFF.
5.
6.
PC400LC-7L
20-111 1
12
ADJUSTING
The unload valve cannot be adjusted.
1.
2.
After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.
20-112 1
PC400LC-7L
12
C. Turn holder (10) to adjust the pressure.
If the holder is
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
Quantity of adjustment per turn of holder: Approximately 258 kg/cm2 (3669 psi).
D. Fixing holder (10), tighten locknut (11).
Locknut: 93 - 123 Nm (68.59 - 90.72 lbf ft)
E. Connect pilot hose (9).
F.
3.
4.
After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.
PC400LC-7L
20-113 1
12
C. Fixing adjustment screw (15), tighten locknut (16).
Locknut: 147 - 196 Nm (108.4 - 144.5 lbf ft)
D. After finishing adjustment, check again that the pressure is normal
according to the procedure for measurement described above.
20-114 1
PC400LC-7L
12
Part No.
799-101-1502
790-261-1203
799-101-5220
07002-11023
Part Name
Hydraulic tester
Digital hydraulic tester
Nipple (10 x 1.25 mm)
O-ring
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1.
Remove the control valve top cover and remove control circuit basic
pressure pick-up plug (1).
The figure shows the control valve seen from inside of the pump
room.
2.
3.
Run the engine and raise the hydraulic oil temperature to the operating
range.
4.
Run the engine at high idling and set all the control levers in neutral
and measure the oil pressure.
5.
PC400LC-7L
20-115 1
12
Part No.
799-101-1502
790-261-1203
799-101-5220
07002-11023
Part Name
Hydraulic tester
Digital hydraulic tester
Nipple (10 x 1.25 mm)
O-ring
MEASURING
Before measuring the oil pressure in the pump PC control circuit, check that the oil pressure in the work equipment,
swing, and travel circuits and the basic pressure in the control circuit are normal.
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1.
20-116 1
PC400LC-7L
C. Run the engine and raise the hydraulic oil temperature to the
operating range.
D. Run the engine at high idling and measure the pump discharge pressure and PC valve output pressure (servo piston
inlet pressure) at the same time under the following condition.
Working mode: A
Swing lock switch: ON (2-stage relief solenoid valve is turned ON and oil is relieved at high pressure)
Work equipment, swing, and travel circuits: Relieve by moving arm IN.
Judging method: If the pump discharge pressure and PC valve output pressure (servo piston output pressure) are
as follows, they are normal.
Measured pressure
Pump discharge pressure
PC valve output pressure
Pressure ratio
1
Approximately 0.6 (3/5)
If the PC valve or servo piston is abnormal, the PC valve output pressure (servo piston output pressure) becomes
the same as the pump discharge pressure or almost 0.
E. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L
20-117 1
12
2. Measuring PC-EPC valve output pressure
A. Open the pump room cover and remove PC-EPC valve output
pressure pick-up plug (5).
C. Run the engine and raise the hydraulic oil temperature to the
operating range.
D. Set all the control levers in neutral and measure the oil pressure while running the engine at low idling and high
idling.
If the PC-EPC valve output pressure changes as shown below, it is normal.
Engine
Control lever
Low idling
Neutral
High idling
Oil pressure
30 kg/cm2
(426.7 psi)
0 kg/cm2
(0 psi)
E. After finishing measurement, remove the measuring instruments and return the removed parts.
20-118 1
PC400LC-7L
12
ADJUSTING
If any of the following phenomena occurs and the PC valve seems to be defective, adjust PC valves (6) and (7) according
to the procedure shown below.
When the working load is increased, the engine speed lowers largely.
The engine speed is normal but the work equipment speed is low.
(6): Front pump PC valve.
(7): Rear pump PC valve.
The width across flats of the locknut for the PC valve is 13 mm
and that of the adjustment screw (inside width) is 4 mm. Do not
turn any other locknut or adjustment screw since it has effects on
the hydraulic pumps.
1.
2.
3.
4.
PC400LC-7L
20-119 1
12
2
3
Part No.
799-101-5002
790-261-1203
799-101-5220
07002-11023
799-401-2701
Part Name
Hydraulic tester
Digital hydraulic tester
Nipple (10 1.25 mm)
O-ring
Differential pressure gauge
MEASURING
Before measuring the oil pressure in the pump LS control circuit, check that the oil pressure in the work equipment,
swing, and travel circuits and the basic pressure in the control circuit are normal.
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1.
20-120 1
PC400LC-7L
C. Run the engine and raise the hydraulic oil temperature to the
operating range and push up the track shoe on the side to be
measured with the work equipment.
When measuring front circuit: Left track shoe.
When measuring rear circuit: Right track shoe.
WARNING! Since the track shoe pushed up will be
driven idle for measurement, secure
sufficient work area.
D. Run the engine at high idling and measure the pump discharge
pressure and LS valve output pressure (servo piston inlet pressure)
at the same time under the following condition.
Working mode: A
Work equipment, swing, and travel control levers: Measure
with all the levers in neutral and measure with only the travel
lever operated halfway (with the track shoe on one side
driven idle).
Check the safety around the machine, drive the track shoe
pushed up idle.
Judging method:
If the pump discharge pressure and LS valve output pressure
(servo piston output pressure) are as follows, they are normal.
Measured pressure
All levers
in neutral
Almost
same
Pressure ratio
Travel lever operated
halfway
1
Approximately 0.6 (3/5)
E. After finishing measurement, remove the measuring instruments and return the removed parts.
2.
PC400LC-7L
20-121 1
C. Run the engine and raise the hydraulic oil temperature to the
operating range and push up the track shoe on the side to be
measured with the work equipment.
When measuring front circuit: Left track shoe.
When measuring rear circuit: Right track shoe
WARNING! Since the track shoe pushed up will be
driven idle for measurement, secure
sufficient work area.
D. Run the engine at high idling and measure the pump discharge
pressure and LS pressure (actuator load pressure) at the same time
under the following condition.
Working mode: A
Travel speed: Hi
Work equipment, swing, and travel control levers: Measure with all the levers in neutral and measure with only
the travel lever operated halfway (with the track shoe on one side driven idle).
Check the safety around the machine, drive the track shoe pushed up idle.
Calculation of LS differential pressure (When oil pressure gauge is used): LS differential pressure = Pump
discharge pressure LS pressure.
If the LS differential pressure is as follows, it is normal.
Operation of lever
Set all levers in neutral
Operate travel lever halfway (Run track shoe idle)
LS differential pressure
Unload pressure (See standard values table)
Specified LS differential pressure (See standard values table)
E. After finishing measurement, remove the measuring instruments and return the removed parts.
20-122 1
PC400LC-7L
12
3. Measuring LS-EPC valve output pressure.
A. Open the pump room cover and remove LSEPC valve output
pressure pick-up plug (7).
C. Run the engine and raise the hydraulic oil temperature to the
operating range.
D. Operate the travel speed switch and travel lever and measure the
oil pressure while running the engine at high idling.
If the LS-EPC valve output pressure changes as shown below,
it is normal.
Travel speed
Lo
Travel lever
Neutral
Oil pressure
30 kg/cm2 (427 psi)
Hi
0 kg/cm2 (0 psi)
Remark
Operate the travel lever to a degree that the PPC oil pressure
switch is turned ON (Stop before the machine starts
traveling).
E. After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L
20-123 1
12
ADJUSTING
If the LS differential pressure is abnormal, adjust LS valves (8) and (9)
according to the following procedure.
(8): Front pump LS valve.
(9): Rear pump LS valve.
1.
2.
3.
20-124 1
PC400LC-7L
12
Part No.
799-101-5002
790-261-1203
799-401-3100
799-401-3200
Part Name
Hydraulic tester
Digital hydraulic tester
Adapter (Size 02)
Adapter (Size 03)
Before measuring the solenoid valve output pressure, check that the basic pressure in the control circuit is normal.
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1.
Remove the control valve top cover and disconnect outlet hose (1) (7) of the solenoid valve to be removed.
Since the outlet hoses of the PPC lock solenoid valves have quick couplers on the solenoid valve side, measure the
pressure on the PPC valve side (on the back side of the operators cab)
.
No.
1
2
3
4
5
6
7
2.
3.
PC400LC-7L
20-125 1
12
4. Run the engine and raise the engine oil temperature to the operating
range.
5.
Run the engine at high idling, operate the control levers and switches
to turn the solenoid valve ON or OFF, and measure the oil pressure.
For the conditions for turning the solenoid valve ON and OFF, see
the operations table of each solenoid valve.
The operating condition of the solenoid valve can be checked with
the monitoring function of the monitor panel (For the operating
method, see Monitor Panel - Special Functions).
Output pressure
OFF (Deenergized)
0 kg/cm (0 psi)
ON (Energized)
6.
After finishing measurement, remove the measuring instruments and return the removed parts.
Operation
OFF
When all of work equipment, swing, and travel signals are turned OFF
When swing lock switch is turned ON
When travel signal is turned ON
When in L-mode
ON
OFF
OFF
ON
Operation
ON
OFF
Work equipment,
swing, travel signal
20-126 1
Operation
OFF
ON
PC400LC-7L
12
Operation table of travel speed shifting solenoid valve
Operating condition
Operation
OFF
ON
Operating condition
When service signal is turned ON
When travel operation is performed singly
Operation
ON
OFF
ON
OFF
ON
OFF
Operation
ON
OFF
PC400LC-7L
OFF
ON
20-127 1
12
1
2
Part No.
799-101-5002
790-261-1203
790-301-1740
Part Name
Hydraulic tester
Digital hydraulic tester
Joint (PF 1/4 + PT 1/8)
WARNING! Lower the work equipment to the ground and stop the engine. Operate the control levers
several times to release the residual pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the internal pressure of the hydraulic tank.
1.
Remove the control valve top cover and operators cab undercover.
2.
Disconnect PPC oil pressure switch or PPC pressure sensor (1) - (10) of the solenoid valve to be removed.
If the starting switch is turned ON while the arm IN or bucket
CURL PPC pressure sensor is disconnected, an electrical
equipment system error is detected. Accordingly, if the pressure
sensor is removed, connect it to the connector again and clamp it
to the nearest bracket, etc.
No.
1
2
3
4
5
6
3.
Circuit to be measured
Boom RAISE (S06)
Boom LOWER (S02)
Arm IN (S04)
Arm OUT (S08)
Bucket CURL (S01)
Bucket DUMP (S05)
No.
7
8
9
10
Circuit to be measured
Swing LEFT (S07)
Swing RIGHT (S03)
Travel (S30)
Steering (S31)
Install joint Q2 and nipple [1] of hydraulic tester Q1 and connect them
to oil pressure gauge [2].
Use joint Q2 only when measuring the pressure at the pressure
sensor mounting part.
Use the oil pressure gauges of 60 kg/cm2 (853 psi)
The figure shows the measuring instruments installed to the
mounting part of the arm IN PPC pressure sensor.
20-128 1
PC400LC-7L
12
4. Run the engine and raise the engine oil temperature to the operating
range.
5.
Run the engine at high idling and measure the oil pressure while the control lever of the measured circuit is in neutral and
while it is operated to the stroke end.
If the PPC valve output pressure is as follows, the solenoid valve is normal.
Operation of lever
In neutral
Operated to stroke end
6.
Output pressure
0 kg/cm2 (0 psi)
Almost same as control basic
pressure (See standard values table)
After finishing measurement, remove the measuring instruments and return the removed parts.
PC400LC-7L
20-129 1
12
2.
3.
Loosen locknut (2) and tighten disc (3) until it touches the heads of 4
pistons (4).
Do not move the piston at this time.
4.
Fix disc (3) and tighten locknut (2) to the specified torque.
Locknut: 98 - 127 Nm (73 - 93 lbf ft)
5.
6.
20-130 1
PC400LC-7L
12
1.
2.
PC400LC-7L
20-131 1
12
3. Testing PPC valve.
While the pressure in the accumulator is high, set the safety lock lever in the LOCK/FREE position and measure the
lowering distance.
Operate the control lever while the starting switch is in the ON position.
If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the
accumulator.
If there is a difference in the lowering distance between the LOCK position and FREE position, the PPC valve is
defective (it has an internal defect).
20-132 1
PC400LC-7L
12
2.
3.
4.
PC400LC-7L
20-133 1
12
1.
Part No.
Commercially available
Part Name
Measuring cylinder
2.
20-134 1
PC400LC-7L
12
3. Measuring oil leakage from bucket cylinder.
A. Run the engine and raise the engine oil temperature to the operating range.
B. Move the bucket cylinder to the CURL stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the bucket cylinder head side. For details,
see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in
the arm CURL direction only, however).
C. Disconnect hose (3) on the cylinder head side and block the hose
side with a plate.
WARNING! Take care not to disconnect the hose on
the cylinder bottom side.
Use the following part to block the hose side.
07379-01044 (Flange #10)
D. Run the engine at high idling and relieve the bucket circuit by
curling the bucket.
WARNING! Take care not to dump the bucket.
E. Measure the oil leakage for 1 minute after 30 seconds since
relieving is started.
F.
4.
PC400LC-7L
20-135 1
12
5. Measuring oil leakage from travel motor.
A. Remove the travel motor cover.
B. Run the engine and raise the engine oil temperature to the
operating range, and then lock the travel system and stop the
engine.
WARNING! Put pin [1] between the sprocket and track
frame to lock the travel system securely.
C. Disconnect drain hose (5) of the travel motor and block the hose
side with a plug.
Use the following part to block the hose side.
07376-70522 (Plug #05)
D. Run the engine at high idling and relieve the travel circuit.
WARNING! Wrong operation of the lever can cause an
accident. Accordingly, make signs and
checks securely.
Measure the oil leakage for 1 minute after 30 seconds since
relieving is started.
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.
E. After finishing measurement, return the removed parts.
20-136 1
PC400LC-7L
12
Work
Replacing hydraulic oil
1
Air bleeding item
Bleeding air
from
hydraulic
pump
2
Starting
engine
air
Bleeding air Bleeding
swing
from cylinder from
motor
Bleeding air
from travel
motor
Remark
Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1.
2.
Starting engine.
When running the engine after performing step 1, keep its speed at low idling for 10 minutes.
If the engine water temperature is low and the automatic warm-up operation is 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 seconds, and the automatic warm-up operation is reset).
PC400LC-7L
20-137 1
12
3. Bleeding air from cylinder.
If a cylinder was replaced, bleed air from it before connecting the work equipment. In particular, the boom cylinder
does not move to the lowering stroke end, if it is installed to the work equipment.
A. Run the engine at low idling for about 5 minutes.
B. Running the engine at low idling, raise and lower the boom 4 - 5 times.
Stop the piston rod about 100 mm before each stroke end. Do not relieve the oil.
C. Running the engine at high idling, perform step B.
D. Running the engine at low idling, move the piston rod to the stroke end and relieve the oil.
E. Bleed air from the arm cylinder and bucket cylinder according to steps B - D.
4.
5.
Drive the raised track shoe idle slowly for about 2 minutes.
Drive the track shoe on the opposite side idle similarly.
20-138 1
PC400LC-7L
12
6. Check oil level and starting work.
A. Run the engine, retract the arm cylinder and bucket cylinder to the
stroke ends, lower the work equipment to the ground, and stop the
engine.
B. Check the oil level by sight gauge (5) of the hydraulic tank.
If the oil level is between lines H and L, it is normal.
If the oil level is below line L, add new oil.
PC400LC-7L
20-139 1
12
Apply the red (+) test pin to the anode (P) side of the diode
and the black () test pin to the cathode (N) side.
ii.
Apply the red (+) test pin to the cathode (N) side of the diode
and the black () test pin to the anode (P) side.
20-140 1
PC400LC-7L
12
PC400LC-7L
[/
[
[
[
] Return switch
] Move-up switch
] Move-down switch
] Input check switch
20-141 1
The monitor panel has the ordinary functions and special functions and displays various pieces of information on the
multi-display unit.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed by
operating switches.
1.
2.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Operators Menu
Screen to display KOMATSU logo
Function of check before starting
Function of displaying maintenance items
Function of displaying caution items
Function of checking working mode and travel
speed
Function of displaying ordinary screen
Function of adjusting brightness and contrast
of display
Function of adjusting flow rate for breaker and
attachments
Function of checking maintenance information
Function of displaying service meter
Function of checking display LCD
Function of displaying cautions
Function of displaying user code
Function of displaying error code and failure
code
20-142 1
Service Menu
15 Function of monitoring [01]
Function of
Electrical system
16 abnormality
Mechanical system
record [02]
17 Function of maintenance record [03]
18 Function of maintenance mode change [04]
19 Function of phone No. entry [05]
Mode in which key is ON
Function of initial Language
20 setting and default Unit
[06]
With/Without service
circuit
Pump absorption torque
Function
of
Adjustment of flow for
21 adjustment [07]
attachment during
compound operation
Function
of
cylinder
cut out mode operation
22 [09]
PC400LC-7L
(OUTLINE)
Only outline of the operating method is described in this section. For
details of contents and operation of each menu, see OPERATION
MANUAL or the volume of STRUCTURE AND FUNCTION.
1.
2.
3.
4.
PC400LC-7L
20-143 1
12
5. Function of checking working mode and travel speed.
After the screen for check before starting is displayed, the symbol
marks of the working mode and travel speed are displayed in large size
for 2 seconds to urge the operator to check the setting.
6.
7.
8.
20-144 1
PC400LC-7L
12
9. Function of checking maintenance information.
The operator can check the detailed information about the
maintenance items (set time and elapsed time) and reset them after
checking with the maintenance switches.
The maintenance function is set and reset and the maintenance
time is set with the service menu.
PC400LC-7L
20-145 1
12
13. Function of displaying user code.
If the machine has any failure, the corresponding user code is
displayed to urge the operator to take a proper remedy, depending on
the degree of the failure.
If any switch is operated while the user code is displayed, the
service code and failure code screen appears (See 14).
Failure mode
E02
E03
E10
E11
E14
E15
E0E
20-146 1
PC400LC-7L
12
14. Function of displaying error code and failure code.
While a user code is displayed, if the following switches are operated,
the phone mark (if registered), phone No. (if registered), error code,
and failure code are displayed in order.
Operation of switch: []
The following are displayed in order repeatedly as the switch is
operated.
(1) Phone mark
The phone mark and phone No. are displayed only when the
phone No. is registered in the monitor panel. The phone No. is
registered, changed, or deleted with the service menu.
For details of the displayed error code and failure code, see the
error codes and failure codes table.
PC400LC-7L
20-147 1
12
Table for Error and Failure Code Nos.
-----------
E112
E113
E114
E115
E116
DY2DKB
DYDEKB
DY2CKB
DY20KA
DY20MA
---
DAC0KR
Engine Controller
---
Pump Controller
DAFRMC
DW91KB
E03
DW45KB
---
DWJ0KB
---
DWK0KB
---
DW43KB
---
DW91KA
E03
DW45KA
---
DWJ0KA
---
DWK0KA
---
DW43KA
---
DA2SKQ
DA2SKA
---------
E222
E223
E224
E225
DXE0KB
DXE0KA
DHPAMA
DHPBMA
---
DA25KP
----E02
DLE2MA
D196KB
DXA0KB
Monitor CAN
Communication
Travel Neutral Solenoid
Valve
Swing Holding Brake
Solenoid Valve
Pump Merge-divider
Solenoid Valve
2-stage Relief Solenoid
Valve
Travel Speed Hi/Lo
Selector Solenoid Valve
Travel Neutral Solenoid
Valve
Swing Holding Brake
Solenoid Valve
Pump Merge-divider
Solenoid Valve
2-stage Relief Solenoid
Valve
Travel Speed Hi/Lo
Selector Solenoid Valve
Pump Controller Model
Selection Wiring Harness
Pump Controller S-NET
Communication
LS-EPC Solenoid Valve
LS-EPC Solenoid Valve
F Pump Pressure Sensor
R Pump Pressure Sensor
Pump Controller Power
Supply Output
Engine Speed Sensor
ATT Selector Relay
TVC Solenoid Valve
E0E
---
E0E
20-148 1
Contents
Code
Component
Trouble
Short Circuit
Short Circuit
Short Circuit
Disconnection
Malfunction
Defective communication
(Abnormality in related
component)
Defective communication
(Abnormality in related
component)
Defective Operation
Short Circuit
Short Circuit
Short Circuit
Short Circuit
Electrical system
Code
History
division
Failure code
User
code
Error code
Short Circuit
Disconnection
Disconnection
Disconnection
Disconnection
Disconnection
Disagreement of Model
Selection Signals
Disconnection
Short Circuit
Disconnection
Malfunction
Malfunction
Lowering of Output Voltage
Malfunction
Short Circuit
Short Circuit
PC400LC-7L
12
E02
---------
E233
E238
E245
E246
E247
Contents
PC-EPC Sol. Disc.
Service Return Relay Disc.
Service Current EPC S/C
Service Current EPC Disc.
Arm Curl PPC Sen. Abnormality
Code
DXA0KA
D196KA
DXE4KB
DXE4KA
DHS3MA
Component
TVC Solenoid Valve
ATT Selector Relay
ATT Flow Throttle EPC Valve
ATT Flow Throttle EPC Valve
Arm IN PPC Pressure Sensor
Bucket CURL PPC Pressure
Sensor
---
DHS4MA
---
DHX1MA
DA2RMC
---
D110KB
E11
DLE3LC
NE Speed Sensor
E11
DLH1LC
G Speed Sensor
E11
DB29KQ
E11
DB20KQ
Engine Controller
E14
DK10KX
E15
DGE2KX
E15
DDE2L6
E11
E15
DH30KX
DGE4KX
E0E
DB2RMC
DD11KB
E0E
DB2SMC
E10
DB22KK
E15
D1D0KB
---
DB2AMA
E15
DGE3L6
E11
E11
E11
E11
E11
E970
E971
E974
E975
E977
AD11KB
AD51KB
AD11KA
AD51KA
DH40KX
E0E
---
PC400LC-7L
History
division
Code
Failure code
Trouble
Disconnection
Disconnection
Short Circuit
Disconnection
Malfunction
Malfunction
Malfunction
Defective Operation
Short Circuit
Disagreement of Speed
Signal
Disagreement of Speed
Signal
Disagreement of Model
Selection Signals
Disagreement of Model
Selection Signals
Out of input signal range
Out of input signal range
Disagreement of signal
with operation of engine
Out of input signal range
Out of input signal range
Electrical system
User
code
Error code
Defective Operation
Short circuit
Defective Operation
Lowering of source
voltage (Input)
Short Circuit
Malfunction
Disagreement of signal
with operation of engine
Short Circuit
Short Circuit
Disconnection
Disconnection
Out of input signal range
20-149 1
Code
Contents
E11
E11
E15
E11
E11
E11
E11
E11
E11
E11
E11
E11
E11
E11
E22
-----------------
E97A
E97B
E97C
E97D
E980
E981
E982
E983
E984
E985
E986
E98A
E98B
E922
Failure code
Code
AD00L2
AD00MA
AD10L3
AD10MB
AD10MA
DB20KT
ADA1KA
ADB1KA
ADC1KA
ADD1KA
ADE1KA
ADF1KA
ADAZKB
ADDZKB
A000N1
A000N2
AA10NX
AB00KE
B@BAZG
B@BAZK
B@BCNS
B@BCZK
B@HANS
Component
History
division
Error code
Trouble
Electrical
system
User
code
12
Mechanical system
The items in this table are arranged in the order of the error codes.
The error codes having no numbers in the user code column and the failure codes having no numbers in the user code
column and error code column are not displayed on the normal screen, even if abnormality related to them occurs. They
are simply recorded in the failure history of the service menu (Electrical equipment system or mechanical equipment
system).
The history division column shows in which division each failure is classified, the electrical equipment system or
mechanical equipment system, when it is recorded in the failure history.
Letter E at the head of each error code indicates the following condition.
With E: The failure has not been repaired yet.
Without E: The failure has been repaired.
20-150 1
PC400LC-7L
B. Operating switches.
Operate the following switches.
Operation of switches: [] [1] [2] [3] (While
pressing [], press the numeral keys)
C. Displaying menu screen.
The initial screen of the service menu is displayed. Select a menu
which you will use.
No.
00
01
02
03
04
05
06
07
09
Service menu
Return (Finish service menu)
Monitoring
Abnormality record
Maintenance record
Maintenance mode change
Phone number entry
Initial setting/Default
Adjust
Cylinder cut out mode operation
PC400LC-7L
20-151 1
12
15. Function of monitoring [01].
The monitor panel monitors the signals from various switches,
sensors, and actuators installed to various parts of the machine. The
operator can display and check the monitoring information in real time
by the following operation.
A. Selecting menu.
On the initial screen of the service menu, select 01 Monitoring
and press the [] switch.
20-152 1
PC400LC-7L
12
D. Function of holding monitoring information.
If the [] switch is pressed during the monitoring operation, all
the monitoring information is held. If the [] switch is pressed
while the monitoring information is held, the monitoring
information is released.
PC400LC-7L
20-153 1
12
Monitoring items list
00000
99999
00200
00201
01002
01601
01100
01101
Return
To Display Screen
Controller Model Select
Controller Model Select
Engine Speed
2nd Eng. Speed Command
F Pump Pressure
R Pump Pressure
07200
07300
04102
14200
04401
01300
01500
01700
03200
03500
04300
01006
04107
36400
MPa
MPa
C
C
C
mA
mA
mA
V
V
V
r/min
C
MPa
36500
36700
03000
04200
04106
04105
14201
36501
36401
17200
17300
31701
36100
36200
36300
Boost Pressure
Torque Ratio
Fuel Dial Vol.
Fuel Level Sensor Vol.
Eng. Water Temp. Vol. Hi
Eng. Water Temp. Vol. Lo
Fuel Temp. Sensor Vol.
Boost Press. Sensor Vol.
Rail Press. Sensor Vol.
PCV Close Angle
Eng. Control Mode
Throttle Level
Fuel Delivery Command
Rail Pressure Command
Injection Timing Angle
kPa
%
V
V
V
V
V
V
V
CA
Code No.
20-154 1
Monitoring item
%
mm /st
MPa
CA
3
kg/cm2
kg/cm
C
C
C
mA
mA
mA
V
V
V
rpm
C
kg/cm2
kg/cm2
%
V
V
V
V
V
V
V
CA
Numeral
%
mm /st
3
kg/cm
CA
inch
Remarks
Finish Menu
Display and Execution Menu
rpm
rpm
psi
psi
psi
psi
F
F
F
mA
mA
mA
V
V
V
rpm
F
psi
psi
%
V
V
V
V
V
V
V
CA
%
mm3/st
psi
CA
PC400LC-7L
12
Code No.
Monitoring item
01900
Pressure Switch 1
01901
Pressure Switch 2
02300
Solenoid 1
02301
Solenoid 2
02200
Switch Input 1
02201
Switch Input 2
02202
03700
Switch Input 3
Controller Output 1
04500
Monitor Input 1
04501
Monitor Input 2
04502
Monitor Input 3
PC400LC-7L
Swing
Travel
Boom Lower
Boom Raise
Arm Curl
Arm Dump
Bucket Curl
Bucket Dump
Service
Travel Steering
Travel Junction
Swing Brake
Merge-divider
2-stage Relief
Travel Speed
Service Return
Lever Sw.
Swing Release Sw.
Swing Brake Sw.
Model Select 1
Model Select 2
Model Select 3
Model Select 4
Model Select 5
Key Switch (ACC)
Batt. Relay Dr.
Key Switch
Start
Preheat
Light
Rad. Level
Aircleaner
Eng. Oil Level
Battery Charge
Swing Brake Sw.
Bzzr Cancel Sw.
Window Limit Sw.
W Limit Sw.
P Limit Sw.
Remarks
20-155 1
12
Codem No.
Monitoring item
17400
36800
36801
05100
S-NET Connection
20200
20212
20209
SI
Key SW (C)
Eng. Oil Press. Lo
Eng. Oil Press. Hi
Machine Sel. 1
Machine Sel. 2
Machine Sel. 3
Pump Controller
Eng. Controller
inch
Remarks
As the unit of display, one of SI unit system, Metric unit system, and Inch unit system can be selected.
The unit of display can be changed with Selecting unit in the Setting initial values function of the service menu.
CA of the unit of display denotes the crankshaft angle.
20-156 1
PC400LC-7L
12
16. Function of abnormality record [02].
The monitor panel classifies and records the past failures into the electrical system group and mechanical system group. The operator can
display and check those failures by the following operation.
A. Selecting menu.
On the initial screen of the service menu, select 02 Abnormality
Record and press the [] switch.
B. Selecting sub-menu.
On the abnormality record menu screen, select a sub-menu and
press the [] switch.
No.
00
01
02
PC400LC-7L
20-157 1
12
E. Resetting electrical system abnormality record.
Only the abnormality record of the electrical system can be
reset (deleted). The abnormality record of the mechanical
system cannot be reset.
If necessary, reset each item or all items of the abnormality
record of the electrical system according to the following
procedure.
i.
ii.
20-158 1
PC400LC-7L
12
17. Function of maintenance record [03].
The monitor panel records the maintenance information about the
filters and oils. The operator can display and check that information by
the following operation.
A. Selecting menu.
On the initial screen of the service menu, select 03 Maintenance
Record and press the [] switch.
B. Displayed information.
(1) Names of oils and filters.
(2) Number of replacement times up to now.
(3) Service meter reading at previous replacement.
PC400LC-7L
20-159 1
Menus 01 and 12 are used to set the whole maintenance mode and menus 02 - 11 are used to set the
items one by one.
C. Contents of setting of maintenance mode On/Off.
On: The function of displaying all the oil and filter items
becomes effective (This setting is applied, even if On/Off
is set for each item).
Off: The function of displaying all the oil and filter items
becomes ineffective (This setting is applied, even if On/
Off is set for each item).
ii.
20-160 1
PC400LC-7L
12
19. Function of phone number entry [05].
The operator can input a phone No. and change it according to the
following procedure. Once the phone No. is input, it and service code
are displayed alternately when the user code is displayed.
If a phone No. is not input, the phone No. screen is not displayed.
A. Selecting menu.
On the initial screen of the service menu, select 05 Phone
Number Entry and press the [] switch.
Input a No. with the numeral keys from the cursor at the left
end.
PC400LC-7L
20-161 1
12
20. Function of initial setting and default [06].
The operator can change the following items related to the monitor
panel and machine, if necessary.
Working mode when starting switch is turned ON.
Language displayed on service menu.
Unit displayed in monitoring function mode.
With/Without attachment.
A. Selecting menu.
On the initial screen of the service menu, select 06 Function of
initial setting and default and press the [] switch.
B. Selecting sub-menu.
Select a sub-menu to change its setting and press the [] switch.
No.
00
01
02
03
04
20-162 1
PC400LC-7L
12
D. Function of setting language.
The operator can select Japanese or English as the language
displayed on the service menu.
The default language of the monitor panel is English.
When using a spare monitor panel in the Japanese language
area, select Japanese with this function.
F.
PC400LC-7L
20-163 1
12
21. Function of adjustment [07].
The operator can adjust various items of the machine on the monitor
panel.
A. Selecting menu.
On the initial screen of the service menu, select 07 Adjustment
and press the [] switch.
B. Selecting sub-menu.
Select a sub-menu to change its setting and press the [] switch.
No.
00
01
02
Sub-menu of adjustment
Return (Finish adjustment)
Pump absorption torque
Adjustment of oil flow for attachment in compound
operation
Adjustment Adjustment
torque
value
+8.0 kgm
225
+6.0 kgm
226
+4.0 kgm
227
+2.0 kgm
228
0.0 kgm
Adjustment
torque
-2.0 kgm
-4.0 kgm
-6.0 kgm
-8.0 kgm
20-164 1
PC400LC-7L
12
22. Function of cylinder cut out mode operation [09].
The operator can operate the machine in the cylinder cut out mode
with the monitor panel. Cylinder cut out mode operation means to run
the engine with 1 or more fuel injectors disabled electrically to reduce
the number of effective cylinders. This operation is used to find out a
cylinder which does not output power normally (or, combustion in it is
abnormal).
A. Selecting menu.
On the initial screen of the service menu, select 09 Cylinder cut
out mode operation and press the [] switch.
PC400LC-7L
20-165 1
12
D. Function of holding engine speed.
If the [] switch is pressed while the reduced cylinder mode
operation screen is used, the engine speed is held and displayed on
the lower line. If the [] switch is pressed while the engine speed
is held, holding of the engine speed is cancelled and the engine
speed displayed on the lower line goes off.
If the holding function is used, the held engine speed is
displayed in ( ) on the lower line and the current engine speed
is displayed on the upper line.
The holding function can be used both in and out of the
cylinder cut out mode.
Run the engine normally (without disabling any cylinder) and hold the
engine speed.
2.
3.
Run the engine under the same condition as the normal operation in
step (1) and compare the engine speed at this time with the held engine
speed.
4.
Cancel the cylinder cut out mode, regardless of the change of the
engine speed.
20-166 1
PC400LC-7L
12
2.
When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.
3.
If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start
the engine.
You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
PC400LC-7L
20-167 1
12
Monitor panel.
A. Remove cover (1).
The cover is fixed with the upper and lower 2 clips. You can
remove the cover by pulling it up.
If the sunlight sensor for the air conditioner is installed,
disconnect connector P15 on the back side of the cover.
2.
Engine controller.
A. Open the right side cover and remove radiator sub tank (3) and
bracket together.
B. Remove the 4 mounting bolts and pull out engine controller (4).
C. Insert or connect T-adapters in or to connectors CB1, CB2, and
CB3 of the engine controller.
Since the connectors are secured with screws, loosen those
screws before disconnecting.
When connecting the connectors again, tighten their screws
to the specified torque.
Screw: 2.82 Nm (2.07 lbf ft)
20-168 1
PC400LC-7L
12
3. Pump controller.
The pump controller is installed inside the cover at the rear of the
operators seat.
A. Remove the 3 mounting bolts and cover (5).
PC400LC-7L
20-169 1
PM CLINIC SERVICE
12
PM CLINIC SERVICE
20-170 1
PC400LC-7L
PM CLINIC SERVICE
12
Positions to install measuring devices (Related to engine)
PC400LC-7L
20-171 1
PM CLINIC SERVICE
12
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
20-172 1
PC400LC-7L
PM CLINIC SERVICE
12
PC400LC-7L
20-173 1
PM CLINIC SERVICE
12
20-174 1
PC400LC-7L
PM CLINIC SERVICE
12
Arm
Boom
Revolving frame
9. Boom bracket
Left
Right
Left
3. Arm top boss
Left
PC400LC-7L
Right
Right
End plate
Left
Right
Track frame
10. Circle bracket
Front
Left
Rear
Right
20-175 1
20-176 1
PM CLINIC SERVICE
PC400LC-7L
TROUBLESHOOTING GENERAL
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . 20-206
HANDLING WIRING HARNESSES AND CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES . . . . 20-208
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-211
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS . . . . . . . . . . . . . . . 20-212
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-212
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
CLASSIFICATION OF TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
STEPS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-215
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS. . . . . . . . . . . . . 20-216
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-231
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-233
T-BRANCH BOX AND T-BRANCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
PC400LC-7L
20-201 b
TROUBLESHOOTING
12
MEMORANDUM
20-202 b
PC400LC-7L
TROUBLESHOOTING
12
WARNING! When disconnecting wiring, always disconnect negative terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, water, or
air, always release the internal pressure first. When installing measuring equipment, be
sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes
of the failure that would produce the reported symptoms.
1.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately any failure occurs:
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil or grease, and at the same time, will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2.
3.
PC400LC-7L
20-203 b
TROUBLESHOOTING
5.
Confirming failure
Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure, then use the
troubleshooting flow chart to locate the position of the failure exactly. The basic procedure for troubleshooting is as
follows.
20-204 b
PC400LC-7L
TROUBLESHOOTING
12
PC400LC-7L
20-205 b
TROUBLESHOOTING
12
2.
20-206 b
PC400LC-7L
TROUBLESHOOTING
12
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 soldering may be damaged, or the wiring may be
broken.
4.
5.
PC400LC-7L
20-207 b
TROUBLESHOOTING
12
REMOVING,
DISCONNECTING CONNECTORS
1.
2.
3.
20-208 b
PC400LC-7L
TROUBLESHOOTING
12
CONNECTING CONNECTORS
1.
2.
3.
Correct any protrusion of the boot and any misalignment of the wiring
harness For connectors fitted with boots, correct any protrusion of the
boot. In addition, if the wiring harness is misaligned, or the clamp is
out of position, adjust it to its correct position.
If the connector cannot be corrected easily, remove the clamp and
adjust the position.
4.
5.
PC400LC-7L
20-209 b
TROUBLESHOOTING
12
DRYING WIRING HARNESS
If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth.
Avoid washing it in water or using steam. If the connector must be washed
in water, do not use high pressure water or steam directly on the wiring
harness. If water gets directly on the connector, do as follows.
1.
Disconnect the connector and wipe off water with a dry cloth.
If the connector is blown dry with compressed air, there is the risk
that oil in the air may cause faulty contact, so remove all oil and
water 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.
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 connector. After drying, leave the
wiring harness disconnected and carry out a continuity test to check
for any short circuits between pins caused by water.
After completely drying the connector, blow it with contact
restorer and reassemble.
20-210 b
PC400LC-7L
TROUBLESHOOTING
12
HANDLING
CONTROL BOX
1.
2.
3.
4.
Cover the control connectors with tape or a vinyl bag. Never touch the
connector contacts with your hand.
5.
During rainy weather, do not leave the control box in a place where it
is exposed to rain.
6.
Do not place the control box on oil, water, or soil, or in any hot place,
even for a short time, place it on a suitable dry stand.
7.
Precautions when carrying out arc welding. When carrying out arc
welding on the body, disconnect all wiring harness connectors
connected to the control box. Fit an arc welding ground close to the
welding point.
PC400LC-7L
20-211 b
TROUBLESHOOTING
12
POINTS
1.
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3.
Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4.
When carrying out troubleshooting of circuits; measuring the voltage, resistance, continuity, or current, move the related
wiring and connectors several times and check that there is no change in the reading of the tester.
If there is any change, there is probably faulty contact in that circuit.
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 on to the ground, collect it and ask the
customer to dispose of it, or take it back with you for disposal.
20-212 b
PC400LC-7L
TROUBLESHOOTING
12
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 cleaning device is used, it is possible to
filter out the dirt that has collected during storage, so this is an even more
effective method.
FLUSHING OPERATIONS
After disassembling and assembling the equipment, 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.
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 circuit. The oil cleaning equipment is
used to remove the ultra fine [about 3] particles that the filter built into the
hydraulic equipment cannot remove, so it is an extremely effective device.
PC400LC-7L
20-213 b
TROUBLESHOOTING
12
Lubricating
oil, coolant
Electrical
equipment
Hydraulic
mechanical
equipment
Electronics,
electrical
equipment
20-214 b
Judgement
value
--------------------------------20 to 30 V
-------
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add water
Clean or replace
Replace
Add oil
Tighten or replace
Tighten or replace
Tighten or replace
Repair
Repair
Bleed air
Replace
Add or replace
Replace
Repair
---
Action
--Replace
After running
for several
Replace
minutes:
27.5 to 29.5 V
--Replace
PC400LC-7L
TROUBLESHOOTING
12
Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
displayed.
Troubleshooting of electrical system
Troubleshooting of hydraulic and mechanical systems
Troubleshooting of engine
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL
Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [] switch to display Error Code. Following displayed Error Code for the
electrical system, carry out the troubleshooting along the corresponding code display.
2.
Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is recorded in the failure
history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system Failure Code,
using the failure history function of the monitor panel.
If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the display again to
check if the same abnormality still persists.
Failure Code in the mechanical system cannot be deleted.
3.
Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that the monitor
panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechanical system. In such a case,
reexamine the phenomenon, find out the most similar phenomenon from among Failure like Phenomena and
Troubleshooting No. and carry out E mode or H mode troubleshooting related to the phenomenon in question.
PC400LC-7L
20-215 b
TROUBLESHOOTING
12
PHENOMENA
NOS.
Remark
TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM (S-MODE) IS IN THE ENGINE SHOP MANUAL.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Display of code
Possible faults related to user code, error code, or failure code
According to
User code is displayed on monitor panel
displayed code
When failure history is checked, error code is displayed in electrical system
When failure history is checked, error code is displayed in mechanical system
Possible faults related to engine
Engine does not start easily (It always takes time to start)
Engine does not start - Engine does not crank
Engine does not start - Engine cranks but exhaust smoke does not come out
Engine does not start - Exhaust smoke comes out but engine does not start
Engine speed does not rise sharply (Follow-up performance is low)
Engine stops during operation
Engine rotation is abnormal (Engine hunts)
Output is insufficient (Power is low)
Exhaust gas color is bad (Incomplete combustion)
Oil is consumed much or exhaust gas color is bad
Oil becomes dirty quickly
Fuel is consumed much
Coolant contains oil (or it blows back or reduces)
Engine oil pressure caution lamp lights up (Oil pressure lowers)
Oil level rises (Water or fuel is mixed in oil)
Water temperature rises too high (Overheating)
Abnormal sound comes out
Vibration is excessive
Engine is not preheated normally
Automatic warm-up function does not work
Automatic decelerator does not work
Possible faults related to work equipment, swing, and travel
Speed or power of whole work equipment, travel, and swing is low
Engine speed lowers extremely or engine stalls
Work equipment, travel, and swing systems do not work
Abnormal sound comes out from around hydraulic pump
Fine control performance or response is low
20-216 b
Troubleshooting
E-mode H-mode
S-1
S-2 a)
S-2 b)
S-2 c)
S-3
S-4
S-5
S-6
S-7
S-8
S-9
S-10
S-11
S-12
S-13
S-14
S-15
S-16
E-1
E-2
E-3
E-4
E-5
S-mode
H-5
H-1
H-2
H-3
H-4
H-6
S-6
S-4
PC400LC-7L
TROUBLESHOOTING
12
Troubleshooting
No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
47
48
50
51
52
53
54
55
56
57
Display of
code
Possible faults related to work equipment
E-mode
PC400LC-7L
H-mode
S-mode
H-7
H-8
H-9
H-10
H-11
H-12
H-13
H-14
H-15
H-30
H-31
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
H-24
H-25
H-26
H-27
H-28
H-29
20-217 b
TROUBLESHOOTING
12
Troubleshooting
No.
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
20-218 b
Display of
code
E-mode
H-mode
S-mode
PC400LC-7L
TROUBLESHOOTING
12
Type
No. of
pins
A01
A02
A03
A04
A05
A06
A07
A09
A10
A11
A12
A13
A14
A15
A16
A20
A21
A22
A23
A31
A33
A34
A35
A40
A41
A42
A43
A44
A50
A51
A52
A60
A61
A73
A80
AL/B
AL/E
AL/R
C01
C02
C03
C09
CB1
CB2
CB3
X
X
DT
SWP
SWP
SWP
SWP
SWP
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
D
X
L
M
Terminal
Terminal
M
D
M
KES0
D
D
X
D
D
DT
Terminal
Terminal
Terminal
DRC
DRC
DRC
S
DRC
DRC
DRC
4
4
12
6
14
14
16
8
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
2
1
2
3
3
1
2
2
8
1
1
1
24
40
40
8
24
40
40
PC400LC-7L
Name of device
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Revolving frame grounding
Revolving frame grounding
Revolving frame grounding
Revolving frame grounding
Revolving frame grounding
Revolving frame grounding
Revolving frame grounding
Battery relay (Terminal E)
Battery relay (Terminal BR)
Battery relay (Terminal N)
Battery relay (Terminal B)
Air cleaner clogging sensor
Radiator water level sensor
Fusible link (65 A)
Fusible link (30 A)
Horn (Low tone)
Horn (High tone)
Intermediate connector
Travel alarm
Right headlamp
Windshield washer motor (Tank)
F pump oil pressure sensor
R pump oil pressure sensor
Fuel level sensor
Hydraulic oil temperature sensor
Fuel priming pump
Intermediate connector
Alternator B terminal
Alternator E terminal
Alternator R terminal
Pump controller
Pump controller
Pump controller
Model selection connector (Pump controller)
Pump controller
Pump controller
Pump controller
Stereogram
T-1
T-1
N-2
O-1
T-1
O-1
S-1
N-2
H-2
I-2
I-2
I-2
F-1
J-3
J-3
D-1
D-2
F-2
F-2
H-9
H-9
D-2
G-9
G-9
G-9
H-9
J-3
D-5
L-5
L-8
L-7
G-9
L-5
G-9
S-1
AE-6
AE-6
AE-6
U-9
U-9
W-9
W-9
I-9
I-9
J-9
Address
M
E
circuit circuit
H-6
D-7
H-6
H-6
D-7
H-5
H-5
A-4
I-1
I-1
I-1
I-1
I-1
I-1
L-5
J-6
J-5
J-6
K-4
K-5
K-6
K-6
D-7
F-1
F-1
D-8
D-9
P
circuit
G-7
G-7
G-7
G-6
G-6
G-5
G-5
G-5
J-8
J-8
J-8
J-8
K-8
K-9
K-9
K-9
K-9
K-9
K-9
J-7
K-5
K-7
K-5
L-5
L-5
K-4
K-5
H-3
D-6
G-4
A-3
A-3
A-2
A-8
A-8
K-1
K-1
A-6
A-5
A-3
A-8
A-7
A-6
B-1
L-8
L-8
20-219 b
TROUBLESHOOTING
12
Connector
No.
Type
No. of
pins
CB5
CN1
CN2
CN3
CN4
CN5
CN6
D01
D02
E06
ENE
ER02
ER03
F02
FB1
G
GND
GND2
GND3
H08
H09
H10
H11
H12
H15
HT/B
HT/S
J01
J02
J03
J04
J05
J06
J07
J08
K19
K30
K31
M07
M09
M13
M19
M21
M22
M23
M26
M27
M29
M30
M31
M32
DT
DT
DT
DT
DT
DT
DT
SWP
SWP
M
DT
HD30
HD30
M
YAZAKI
DT
Terminal
Terminal
M
S
S
S
S
S090
Terminal
Terminal
J
J
J
J
J
J
J
J
M
DT
DT
M
M
M
YAZAKI
PA
Y090
Y090
S
YAZAKI
040
040
M
M
8
2
2
2
2
2
2
8
8
3
2
31
31
2
2
2
1
1
8
8
16
16
12
20
1
1
20
20
20
20
20
20
20
20
2
3
3
3
1
2
2
9
2
2
12
18
20
16
2
2
20-220 b
Name of device
Model selection connector (Engine controller)
No. 1 fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
No. 5 fuel injector
No. 6 fuel injector
Concentrated diode
Concentrated diode
Fuel control dial
Engine speed sensor
Intermediate connector
Intermediate connector
Rotary lamp
Fuse box
Engine G sensor
Joint connector (with diode)
Engine grounding
Engine grounding
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Intermediate connector
Heater relay B terminal
Heater relay S terminal
Junction connector (Black)
Junction connector (Black)
Junction connector (Green)
Junction connector (Green)
Junction connector (Pink)
Junction connector (Orange)
Junction connector (Orange)
Junction connector (Pink)
Pump resistor (For driving pump in emergency)
CAN terminal resistance
CAN terminal resistance
Light switch
Working lamp (Right front)
Speaker (Right)
Cigarette lighter
Radio
Horn switch
One-touch power maximizing switch
Intermediate connector
Air conditioner unit
Air conditioner control panel
Air conditioner control panel
Optional power supply (2)
Optional power supply (1)
Address
M
Stereogram circuit
J-9
AI-2
AI-3
AJ-3
AJ-5
AJ-6
AJ-6
W-7
A-9
W-5
A-8
P-7
AJ-5
AF-8
J-3
AF-8
AA-9
V-2
I-9
AH-2
AJ-6
AJ-5
AE-7
W-6
J-8
W-6
J-8
T-9
D-6
S-9
D-6
S-9
D-5
O-7
C-2
AH-9
AJ-7
T-9
C-9
T-9
D-9
U-9
D-9
V-3
E-9
V-3
E-9
W-3
F-9
W-5
F-9
W-5
W-5
K-9
A-2
N-4
A-4
P-8
C-1
E-9
K-7
AC-9
N-3
U-2
O-7
T-1
W-4
W-4
U-2
U-2
W-7
W-6
E
circuit
A-7
K-3
K-2
K-2
K-2
K-3
K-2
P
circuit
A-4
A-4
K-7
I-5
I-3
K-6
E-7
K-3
G-8
I-7
E-2
E-2
E-2
A-2
I-6
I-7
H-9
H-9
H-9
I-9
I-9
I-9
A-9
K-6
B-9
C-1
C-9
C-9
D-9
D-9
D-9
E-9
B-1
I-3
E-1
F-9
PC400LC-7L
TROUBLESHOOTING
12
Connector
No.
Type
No. of
pins
M33
M33
M34
M37
M38
M38
M40
M41
M42
M43
M45
M46
M71
M72
M73
M79
NE
OL
P01
P02
P03
P05
P15
P70
PCV1
PCV2
PSH
PSL
PFUEL
PIM
R10
R11
R13
R20
R22
R30
R31
S01
S02
S03
S04
S05
S06
S07
S08
S09
S10
S11
S14
S21
S22
M
SUMITOMO
X
Terminal
Terminal
M
M
M
M
M
D
X
M
M
M
M
YAZAKI
DT
070
040
M
M
Y050
040
SUMITOMO
SUMITOMO
Terminal
Terminal
AMP
SUMITOMO
R
R
R
R
R
R
R
D
X
X
D
X
X
X
X
X
X
X
M
Terminal
Terminal
2
4
1
1
1
2
2
2
1
1
12
4
2
4
2
2
2
2
12
20
2
2
2
16
2
2
1
1
3
3
5
5
5
5
5
5
5
4
2
2
3
2
2
2
2
2
2
2
3
6
6
PC400LC-7L
Name of device
Optional power supply (3)
Air conditioner unit
Air conditioner compressor electromagnetic clutch
Horn switch (High tone)
Horn switch (Low tone)
Machine push-up switch
Working lamp
Working lamp (Additional)
Intermediate connector
Working lamp (Rear)
Intermediate connector
RS232C junction connector
Room lamp
DC/DC converter
Speaker (Left)
12-V accessory outlet
Engine Ne sensor
Engine oil level sensor
Monitor panel
Monitor panel
Buzzer cancel switch
Rotary lamp switch
Air conditioner daylight sensor
Monitor panel
Fuel supply pump PCV1
Fuel supply pump PCV2
Engine oil pressure switch (High pressure)
Engine oil pressure switch (Low pressure)
Common rail pressure sensor
Boost pressure sensor
Light relay
Starting motor cutout relay (PPC lock)
Starting motor cutout relay (Personal code)
ATT circuit selector relay
Power supply relay for engine controller
Air conditioner blower relay
Air conditioner compressor relay
Bucket CURL pressure sensor
Boom LOWER oil pressure switch
Swing RIGHT oil pressure switch
Arm IN pressure switch
Bucket DUMP oil pressure switch
Boom RAISE oil pressure switch
Swing LEFT oil pressure switch
Arm DUMP oil pressure switch
Service oil pressure switch (Intermediate connector)
Service front oil pressure switch
Service rear oil pressure switch
Safety lock lever switch
Emergency pump drive switch
Swing holding brake release switch
Stereogram
V-9
W-4
I-9
H-1
G-1
Q-8
Z-8
Y-7
H-9
J-9
W-7
V-9
AA-8
U-2
AD-8
V-9
AJ-5
AJ-3
N-6
N-5
Q-8
U-2
N-5
N-5
AH-2
AI-2
AH-2
AG-1
AJ-4
AJ-8
P-7
P-8
Q-8
W-7
W-6
W-4
W-3
K-3
L-2
L-2
K-3
L-2
L-2
L-2
L-1
L-1
K-1
L-1
S-1
R-9
R-8
Address
M
E
circuit
circuit
P
circuit
A-1
K-8
K-8
J-7, K-7
K-7
A-4
K-4
K-2
A-7
A-6
D-1
A-5
K-7
K-6
E-1
E-1
K-6
K-1
K-1
L-5
L-5
K-5
K-5
E-1
E-1
E-1
F-1
E-9
G-9
K-9
K-3
K-2
K-2
K-3
K-2
K-2
K-2
K-2
K-1
K-1
K-1
E-9
C-1
D-1
20-221 b
TROUBLESHOOTING
12
Connector
No.
Type
No. of
pins
S25
S30
S31
ST
ST/B
T05
T06
T06A
T11
THL
TWH
TWL
V01
V02
V03
V04
V05
V06
V08
V12
V21
V22
V30
W03
W04
X05
S090
X
X
DT
Terminal
Terminal
Terminal
M
Terminal
DT
DT
DT
DT
DT
D
D
D
D
D
D
D
D
X
M
M
M
16
2
2
2
1
1
1
1
1
3
2
3
2
2
2
2
2
2
2
2
2
2
2
2
6
4
20-222 b
Name of device
Intermediate connector
Travel oil pressure switch
Travel steering oil pressure switch
Starting motor
Starting motor B terminal
Floor frame grounding
Radio body grounding
Intermediate connector
Cab grounding
Spill fuel temperature sensor
Engine water temperature sensor (High temperature)
Engine water temperature sensor (Low temperature)
PPC oil pressure lock solenoid valve
Travel junction solenoid valve
Merge-divider solenoid valve
Travel speed solenoid valve
Swing holding brake solenoid valve
Machine push-up solenoid valve
2nd-stage relief solenoid valve
ATT return selector solenoid valve
PC-EPC solenoid valve
LS-EPC solenoid valve
ATT flow adjustment EPC solenoid valve
Rear limit switch (Window)
Wiper motor
Swing lock switch
Stereogram
R-9
P-1
P-1
AF-7
AF-7
V-3
S-9
T-2
Address
M
E
circuit circuit
K-3
P
circuit
C-2
A-9
A-9
K-6
J-8
K-8
AJ-4
AE-7
AG-8
J-3
J-2
J-2
J-2
J-2
J-2
J-1
J-1
L-6
L-6
P-1
AB-9
Y-5
Q-8
K-3
K-5
K-5
K-5
K-5
K-4
K-4
K-4
K-4
K-4
K-4
L-7
L-7
F-1
K-8
B-9
D-2
A-1
PC400LC-7L
TROUBLESHOOTING
12
Connector type
D or DT
L
J
M
R
S
X
PA
SWP
DRC
040
070
Y050
S090
Y090
YAZAKI
SUMITOMO
KES0
Terminal
Terminal
PC400LC-7L
Detailed information
Japanese and German makes DT type connector (08192-XXXXX)
Product of Yazaki Corporation L type connector (08056-2XXXX)
Product of Sumitomo Wiring Systems 090 type splice
Product of Yazaki M type connector (08056-0XXXX)
Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
Product of Yazaki S type connector (08056-1XXXX)
Product of Yazaki X type connector (08055-0XXXX)
Product of Yazaki PA type connector
Product of Yazaki SWP type connector (08055-1XXXX)
Japanese and German makes DRC type connector
Product of Japan AMP 040 type connector
Product of Japan AMP 070 type connector
Product of Yazaki 050 type connector
Product of Sumitomo 090 type connector
Product of Yazaki 090 type connector
Yazaki-made connector
Product of Sumitomo Wiring Systems 6098 type connector
KESO type connector (08027-0XXXX)
Round pin type single terminal connector
Round terminal
20-223 b
TROUBLESHOOTING
12
CONNECTOR
20-224 b
LOCATION DIAGRAM
PC400LC-7L
TROUBLESHOOTING
12
PC400LC-7L
20-225 b
TROUBLESHOOTING
12
20-226 b
PC400LC-7L
TROUBLESHOOTING
12
PC400LC-7L
20-227 b
TROUBLESHOOTING
12
20-228 b
PC400LC-7L
TROUBLESHOOTING
12
PC400LC-7L
20-229 b
TROUBLESHOOTING
12
MONITOR
Remark
This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging system,
light system, and communication network system from the general electric circuit diagram.
See FOLDOUT 17 & 18 on pages 90-35 and 90-37.
20-230 b
PC400LC-7L
TROUBLESHOOTING
12
ENGINE
Remark
This circuit diagram is made by extracting the engine controller system from the general electric circuit diagram.
See FOLDOUT 19 & 20 on pages 90-39 and 90-41.
PC400LC-7L
20-231 b
TROUBLESHOOTING
12
PUMP
Remark
This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine push-up
solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
See FOLDOUT 21, 22, 23 & 24 on pages 90-43 thru 90-49.
20-232 b
PC400LC-7L
TROUBLESHOOTING
12
No.of pins
X type connector
Female (male housing)
Part No.: 08055-00191
799-601-7020
799-601-7030
---
---
799-601-7040
PC400LC-7L
---
---
20-233 b
TROUBLESHOOTING
12
No.of
pins
799-601-7050
799-601-7060
12
799-601-7310
14
799-601-7070
20-234 b
T-adapter
Part No.
PC400LC-7L
TROUBLESHOOTING
12
16
---
---
T-adapter
Part No.
799-601-7320
PC400LC-7L
---
---
20-235 b
TROUBLESHOOTING
12
No.of
pins
1
M type connector
Female (male housing)
Part No.: 08056-00181
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
20-236 b
PC400LC-7L
TROUBLESHOOTING
12
No.of
pins
S type connector
Female (male housing)
799-601-7140
10
(White)
799-601-7150
12
(White)
799-601-7350
16
(White)
799-601-7330
PC400LC-7L
20-237 b
TROUBLESHOOTING
12
No.of
pins
S type connector
Female (male housing)
10
(Blue)
---
---
---
12
(Blue)
799-601-7160
16
(Blue)
799-601-7170
20-238 b
PC400LC-7L
TROUBLESHOOTING
12
No.of
pins
7
11
799-601-2710
799-601-2950
13
799-601-2720
PC400LC-7L
20-239 b
TROUBLESHOOTING
12
No.of
pins
17
799-601-2730
21
799-601-2740
20-240 b
---
PC400LC-7L
TROUBLESHOOTING
12
No.of
pins
799-601-7180
---
12
799-601-7190
---
16
799-601-7210
---
20
799-601-7220
---
PC400LC-7L
20-241 b
TROUBLESHOOTING
12
No.of
pins
10
799-601-7510
---
12
799-601-7520
---
14
799-601-7530
---
18
799-601-7540
---
20
799-601-7550
---
20-242 b
PC400LC-7L
TROUBLESHOOTING
12
No.of
pins
L type connector
Female (male housing)
---
---
No.of
pins
---
Connector for PA
Female (male housing)
---
Bendix MS connector
Male (female housing)
10
T-adapter Part
No.
799-601-3460
---
PC400LC-7L
---
---
No.of
pins
---
20-243 b
TROUBLESHOOTING
12
No.of
pins
---
---
Part No.:08027-10310
Part No.:08027-10360
---
---
20-244 b
PC400LC-7L
TROUBLESHOOTING
12
No.of
pins
---
No.of
pins
799-601-7360
---
---
799-601-7370
---
No.of
pins
---
F type connector
Female (male housing)
---
---
PC400LC-7L
---
20-245 b
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)
Body (receptacle)
799-601-9210
18-8 (1)
799-601-9210
799-601-9220
18-14
(2)
799-601-9220
20-246 b
PC400LC-7L
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)
Body (receptacle)
799-601-9230
18-20
(3)
799-601-9230
799-601-9240
18-21
(4)
799-601-9240
PC400LC-7L
20-247 b
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)
Body (receptacle)
799-601-9250
24-9
(5)
799-601-9250
799-601-9260
24-16
(6)
799-601-9260
20-248 b
PC400LC-7L
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)
Body (receptacle)
T-adapter
Part No.
799-601-9270
24-21
(7)
799-601-9270
799-601-9280
24-22
(8)
799-601-9280
PC400LC-7L
20-249 b
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)
Body (receptacle)
799-601-9290
24-31
(9)
799-601-9290
20-250 b
PC400LC-7L
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
DT Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter
Part No.
799-601-9020
799-601-9030
799-601-9040
799-601-9050
PC400LC-7L
20-251 b
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
No.of
pins
Body (plug)
DT Series connector
Body (receptacle)
8GR: 799-601-9060
8B: 799-601-9070
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12G: 799-601-9130
12BR: 799-601-9140
12
20-252 b
PC400LC-7L
TROUBLESHOOTING
12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
DTM Series connector
No.of
pins
Body (plug)
Body (receptacle)
T-adapter Part
No.
799-601-9010
No.of
pins
Body (plug)
---
PC400LC-7L
20-253 b
TROUBLESHOOTING
12
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
---
The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part number of
Harness Checker Assembly.
Part No.
No. of pins
799-601-2600
799-601-3100
799-601-3200
799-601-3300
799-601-3360
799-601-3370
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
799-601-2790
799-601-2810
799-601-2820
799-601-2830
799-601-2840
799-601-2850
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799-601-7060
Measurement box
Measurement box
Measurement box
Measurement box
Plate
Plate
Plate
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
Case
MIC
MIC
MIC
MIC
MIC
ECONO
ECONO
ECONO
ECONO
ECONO
DLI
DLI
DLI
Additional cable
Case
X
X
X
X
SWP
SWP
Econo-21P
MS-37P
MS-37P
Econo-24P
For MS box
For MS box
For MS box
24P
24P
17P
17P
5P
10P
5P
14P
19P
14P
5P
13P
17P
21P
9P
2P
3P
4P
8P
12P
8P
12P
16P
O
O
O
O
O O
O O
OOO
OOO
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
20-254 b
1P
2P
3P
4P
6P
8P
OO
OO
O
O
OO
OO
OOO
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
PC400LC-7L
Part No.
No. of pins
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
SWP
SWP
SWP
M
M
M
M
M
M
12P
14P
16P
1P
2P
3P
4P
6P
8P
PC400LC-7L
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
---
TROUBLESHOOTING
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
20-255 b
TROUBLESHOOTING
No. of pins
799-601-7140
8P
799-601-7150
799-601-7160
799-601-7170
799-601-7330
O O O
10P-White
O O O
12P-Blue
O O O
16P-Blue
O O O
16P-White
799-601-7350
12P-White
799-601-7180
AMP040
8P
799-601-7190
AMP040
12P
799-601-7210
AMP040
16P
O O O
799-601-7220
AMP040
20P
O O O
799-601-7230
Short connector
X-2
O O O
799-601-7240
Case
799-601-7270
Case
799-601-7510
070
10P
799-601-7520
070
12P
799-601-7530
070
14P
799-601-7540
070
18P
799-601-7550
070
20P
799-601-7360
Relay connector
5P
799-601-7370
Relay connector
6P
799-601-7380
JFC connector
2P
799-601-9010
DTM
2P
799-601-9020
DT
2P
799-601-9030
DT
3P
799-601-9040
DT
4P
799-601-9050
DT
6P
799-601-9060
DT
8P-Gray
799-601-9070
DT
8P-Black
799-601-9080
DT
8P-Green
799-601-9090
DT
8P-Brown
799-601-9110
DT
12P-Gray
799-601-9120
DT
12P-Black
799-601-9130
DT
12P-Green
799-601-9140
DT
12P-Brown
799-601-9210
HD30
18-8
20-256 b
---
Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
12
O
O
O
O O
O
O O
PC400LC-7L
Part No.
No. of pins
799-601-9220
HD30
18-14
O O
799-601-9230
HD30
18-20
O O
799-601-9240
HD30
18-21
O O
799-601-9250
HD24
24-9
O O
799-601-9260
HD30
24-16
O O
799-601-9270
HD30
24-21
O O
799-601-9280
HD30
24-23
O O
799-601-9290
HD30
24-31
O O
---
TROUBLESHOOTING
799-601-9310
Plate
For HD30
O O
799-601-9320
Measurement box
For DT, HD
O O
799-601-9330
Case
799-601-9340
Case
799-601-9350
DEUTSCH
40P
799-601-9360
DEUTSCH
24P
799-601-9410
2P
799-601-9420
3P
799-601-9430
PVC socket
2P
PC400LC-7L
O
O
20-257 b
TROUBLESHOOTING
12
20-258 b
Fuse No.
Fuse capacity
10 A
20 A
10 A
10 A
5
6
7
8
10 A
10 A
10 A
10 A
10 A
10
11
10 A
20 A
12
20 A
13
20 A
14
10 A
15
10 A
16
17
18
19
20
10 A
10 A
10 A
10 A
10 A
PC400LC-7L
PC400LC-7L
20-301 1
TROUBLESHOOTING
TABLE OF CONTENTS
20-302 1
PC400LC-7L
TROUBLESHOOTING
TABLE OF CONTENTS
E956 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
ENGINE POWER FAILURE (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
E957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
ENGINE POWER FAILURE (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
E95A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
E970 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
PCV1 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
E971 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
PCV2 OVER CURRENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
E974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
PCV1 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-420
E975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
PCV2 LINE CUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
E977 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
RAIL PRESSURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-424
E979 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
RAIL PRESSURE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
E97A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
RAIL PRESSURE ABNORMAL HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-427
E97B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
RAIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
E97C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
RAIL PRESSURE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
E97D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
RAIL PRESSURE OUT OF CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
E980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
ENGINE CONTROLLER ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-432
E981 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
FUEL INJECTOR 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
E982 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
FUEL INJECTOR 2 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-435
E983 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
FUEL INJECTOR 3 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
E984 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437
FUEL INJECTOR 4 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-437
E985 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
FUEL INJECTOR 5 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-438
E986 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439
FUEL INJECTOR 6 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-439
E98A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
FUEL INJECTOR 1 - 3 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-440
E98B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
FUEL INJECTOR 4 - 6 S/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-442
A000N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
ENGINE HIGH IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-444
A000N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
ENGINE LOW IDLING SPEED OUT OF STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
AA10NX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
AIR CLEANER CLOGGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
AB00KE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
CHARGE VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
B@BAZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
ENGINE OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
B@BAZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
ENGINE OIL LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-452
B@BCNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
PC400LC-7L
20-303 1
TROUBLESHOOTING
TABLE OF CONTENTS
20-304 1
PC400LC-7L
TROUBLESHOOTING
12
MEMORANDUM
PC400LC-7L
20-305 1
TROUBLESHOOTING
12
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3.
Always connect any disconnected connectors before going on to the next step.
If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
If there is any charge, there is probably defective contact in that circuit.
5.
6.
7.
20-306 1
PC400LC-7L
TROUBLESHOOTING
12
POINTS
ITSELF
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1.
2.
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned
to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if
the monitor display returns to normal.
3.
After completing troubleshooting, always erase the user code from memory.
PC400LC-7L
20-307 1
TROUBLESHOOTING
12
Contents Of Trouble
Steps
1.
What you
testing
are
4.
No.
Readings
Resistance
or
Voltage
readings
Your
information
readings
Your
information
Diode test
With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately)
When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical
flow. Electrical flow should be one way only.
A.Diode test
3.
Specifications
Sensor or actuator
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.
2.
Failure.
Failure code displayed.
Additional information.
Resistance
Continuity one
way only?
Yes or No
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.Open or high
resistance
Resistance
or
Voltage
readings
Your
information
readings
Your
information
Resistance
or
Voltage
readings
Your
information
readings
Your
information
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.What you are
testing
20-308 1
Resistance
or
Voltage
readings
Your
information
PC400LC-7L
TROUBLESHOOTING
12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
PC400LC-7L
20-309 1
TROUBLESHOOTING
E101
12
E101
ERROR IN DATA HISTORY
Contents Of Trouble
Steps
Specifications
No.
Readings
Check condition of batteries and connections before proceeding with these tests.
Good
Condition?
Yes or No
Good
Condition?
Yes or No
0.0 to 1.0
0.0 to 1.0
Good?
30 to 20V
30 to 20V
0.0 to 1.0
(OL) open
(OL) open
10
(OL) open
11
(OL) open
12
Fuse tests
Resistance
A.
B.
3.
Yes or No
Voltage
Resistance
Resistance
Disconnect P01 connector from monitor panel and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
Voltage
Resistance
20-310 1
30 to 20V
30 to 20V
13
14
0.0 to 1.0
15
PC400LC-7L
TROUBLESHOOTING
E101
12
Electrical circuit diagram for E101 error in data history
PC400LC-7L
20-311 1
TROUBLESHOOTING
E112
12
E112
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM
Contents Of Trouble
Steps
1.
A.
Wiper motor
Voltage
Resistance
2.
No.
Readings
(OL) open
Disconnect P01 connector from controller and install T-adapter between P01 connector and monitor panel.
Disconnect P02 connector from controller and install T-adapter between P02 connector and monitor panel.
A.
B.
3.
Specifications
Wiper motor
Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
Open or high
resistance
Short to chassis
ground or within
harness
Resistance
Resistance
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
(OL) open
(OL) open
10
(OL) open
11
(OL) open
12
(OL) open
13
(OL) open
14
(OL) open
15
(OL) open
16
(OL) open
17
(OL) open
18
Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
20-312 1
Voltage
20 to 30V cycling
19
0V
20
PC400LC-7L
TROUBLESHOOTING
E112
12
Electrical circuit diagram for the windshield wiper motor
PC400LC-7L
20-313 1
TROUBLESHOOTING
E113
12
E113
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE
Contents Of Trouble
Steps
1.
A.
Wiper motor
Voltage
Resistance
2.
No.
Readings
(OL) open
Disconnect P01 connector from controller and install T-adapter between P01 connector and monitor panel.
Disconnect P02 connector from controller and install T-adapter between P02 connector and monitor panel.
A.
B.
3.
Specifications
Wiper motor
Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
Open or high
resistance
Short to chassis
ground or within
harness
Resistance
Resistance
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
(OL) open
(OL) open
10
(OL) open
11
(OL) open
12
(OL) open
13
(OL) open
14
(OL) open
15
(OL) open
16
(OL) open
17
(OL) open
18
Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
20-314 1
Voltage
20 to 30V cycling
19
0V
20
PC400LC-7L
TROUBLESHOOTING
E113
12
Circuit diagram for monitor panel wiper motor.
PC400LC-7L
20-315 1
TROUBLESHOOTING
E114
12
E114
SHORT OR OPEN IN WINDOW WASHER SYSTEM
Contents Of Trouble
B.
Readings
Washer motor
Voltage
20 to 30V
0V
Open or high
resistance
Short to chassis
ground or within
harness
Voltage
Resistance
Resistance
20 to 30V
0.0 to 1.0
(OL) open
(OL) open
Continuity one
way only?
Diode test
4.
No.
Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
3.
Specifications
Washer motor
Disconnect A05 connector from motor and install T-adapter between motor and connector A05.
2.
Steps
1.
Diode test
Resistance
Yes or No
Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
20-316 1
Voltage
20 to 30V
0V
PC400LC-7L
TROUBLESHOOTING
E114
12
Monitor panel window washer motor circuit diagram
PC400LC-7L
20-317 1
TROUBLESHOOTING
E115
12
E115
ABNORMAL WIPER MOTOR OPERATION
Contents Of Trouble
No.
Readings
Wiper motor
Resistance
0.0 to 1.0
(OL) open
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
(OL) open
(OL) open
10
(OL) open
11
(OL) open
12
(OL) open
13
(OL) open
14
(OL) open
15
(OL) open
16
Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
A.
B.
3.
Specifications
Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
A.
2.
Steps
1.
Open or high
resistance
Short to chassis
ground or within
harness
Resistance
Resistance
Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
20-318 1
Voltage
0V
17
20 to 30V
18
PC400LC-7L
TROUBLESHOOTING
E115
12
Monitor panel windshield wiper motor circuit diagram
PC400LC-7L
20-319 1
TROUBLESHOOTING
E116
12
E116
ABNORMALITY IN PARKING WIPER ARM
Contents Of Trouble
No.
Readings
Wiper motor
Resistance
0.0 to 1.0
(OL) open
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
(OL) open
(OL) open
10
(OL) open
11
(OL) open
12
(OL) open
13
(OL) open
14
(OL) open
15
(OL) open
16
Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.
A.
B.
3.
Specifications
Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
A.
2.
Steps
1.
Open or high
resistance
Short to chassis
ground or within
harness
Resistance
Resistance
Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.
Monitor panel
20-320 1
Voltage
0V
17
20 to 30V
18
PC400LC-7L
TROUBLESHOOTING
E116
12
Monitor panel wiper motor circuit diagram
PC400LC-7L
20-321 1
TROUBLESHOOTING
E117
12
E117
ENGINE CONTROLLER S-NET COMMUNICATION ERROR
Contents Of Trouble
The monitor panel detected communication failure in the S-NET communication circuit to the engine controller.
Failure code DAC0KR.
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)
Relative information
Steps
1.
A.
B.
2.
Readings
Open or high
resistance
Resistance
Grounding fault
wiring harness
(Contact with
grounding circuit)
of
Resistance
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
Above 1 M
Above 1 M
Short-circuit (Contact
with 24V circuit)
Voltage
0V
0V
6 - 9V
6 - 9V
6 - 9V
10
6 - 9V
11
Engine controller
4.
No.
3.
Specifications
Defective
test
controller
Voltage
20-322 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E117
12
Engine controller S-net communication circuit diagram
PC400LC-7L
20-323 1
TROUBLESHOOTING
E118
12
E118
PUMP CONTROLLER S-NET COMMUNICATION ERROR
Contents Of Trouble
The monitor panel detected communication failure in the S-NET communication circuit to the pump controller.
Failure code DAB0KR.
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)
Relative information
Steps
1.
A.
B.
2.
Readings
Open or high
resistance
Resistance
Grounding fault
wiring harness
(Contact with
grounding circuit)
of
Resistance
Between P02 (9), (10) monitor panel and CB2 (21), (31)
engine controller
0.0 to 1.0
Between P02 (9), (10) monitor panel and C02 (21) pump
controller
0.0 to 1.0
0.0 to 1.0
Above 1 M
Above 1 M
Short-circuit (Contact
with 24V circuit)
Voltage
0V
0V
6 - 9V
6 - 9V
10
6 - 9V
11
Pump controller
4.
No.
3.
Specifications
Defective
test
controller
Voltage
20-324 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E118
12
Pump controller S-net communication circuit diagram
PC400LC-7L
20-325 1
TROUBLESHOOTING
E128
12
E128
MONITOR COMMUNICATION ABNORMALITY
The monitor panel detected communication failure in the CAN communication circuit to the engine controller or pump
controller.
Failure code DAF0MC.
Contents Of Trouble
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Relative information
---
Steps
1.
A.
No.
Open or high
resistance
Resistance
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
0.0 to 1.0
Above 1 M
Above 1 M
Above 1 M
Above 1 M
Above 1 M
10
Above 1 M
11
0V
0V
0V
0V
0V
10
0V
11
B.
2.
Specifications
Readings
Grounding fault
wiring harness
(Contact with
grounding circuit)
of
Resistance
A.
Short-circuit (Contact
with 24V circuit)
20-326 1
Voltage
PC400LC-7L
TROUBLESHOOTING
Steps
3.
Specifications
No.
Readings
Hold the ignition switch in the OFF position for this test
A.
4.
E128
Defective CAN
resistor tests
Resistance
40 - 80
12
40 - 80
13
If causes 1 - 3 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices,
troubleshooting cannot be carried out.)
PC400LC-7L
20-327 1
TROUBLESHOOTING
E201
12
E201
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
When power was turned on, there was abnormal current supplied to the travel interlocking circuit.
Failure code DW91KB.
It is difficult to steer the machine at turns. (LH and RH travel circuits cannot be disconnected).
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
Steps
1.
A.
2.
No.
Readings
Resistance
Solenoid test
20 to 60
(OL) open
Above 1M
0V
20 - 30V
3.
Specifications
Solenoid test
Ground
fault
test
(Contact with
grounding circuit)
Resistance
Pump controller
Defective
test
controller
Voltage
20-328 1
PC400LC-7L
TROUBLESHOOTING
E201
12
MEMORANDUM
PC400LC-7L
20-329 1
TROUBLESHOOTING
E203
12
E203
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
When power was turned on, there was abnormal current supplied to the swing holding brake solenoid circuit.
Failure code DW45KB.
Power supply to the swing holding brake solenoid circuit is switched OFF.
Even if the failure cause disappears of itself, the swing and steering brake does not return to normal, unless the engine
starting switch is turned OFF.
The upper structure cannot swing. (The swing holding brake cannot be released.
Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing
holding brake release switch to the RELEASE position.
(In this case, however, the holding brake does not work, when stopping the machine.)
Steps
1.
A.
2.
Readings
20 to 60
Above 1M
Resistance
Diode test
Continuity one
way only?
Disconnect S25 and X05 connectors from swing lock and park brake switches.
Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 wire harness connectors only.
A.
B.
4.
No.
Diode test
3.
Specifications
Solenoid test
Open or high
resistance
Resistance
Short
to
chassis
ground or within
harness
Resistance
Above 1M
Above 1M
Above 1M
Above 1M
Above 1M
Above 1M
(OL) open
10
(OL) open
11
0V
12
20 - 30V
13
Pump controller
Defective
test
20-330 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E203
PC400LC-7L
20-331 1
TROUBLESHOOTING
E204
12
E204
SHORT IN MERGE/DIVIDE SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
In L mode, the work equipment moves slowly or the swing speed is slow in single operation. (FR pumps cannot be
disconnected).
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
Steps
1.
A.
2.
3.
Specifications
No.
Readings
Solenoid test
20 to 60
Above 1M
Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.
Open or high
resistance
Resistance
B.
Short
to
chassis
ground or within
harness
Resistance
Above 1M
(OL) open
(OL) open
0V
20 - 30V
Pump controller
Defective
test
20-332 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E204
PC400LC-7L
20-333 1
TROUBLESHOOTING
E205
12
E205
SHORT IN 2-STAGE RELIEF SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
Steps
1.
A.
2.
3.
Specifications
No.
Readings
Solenoid test
20 to 60
Above 1M
Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.
Open or high
resistance
Resistance
B.
Short
to
chassis
ground or within
harness
Resistance
Above 1M
(OL) open
(OL) open
0V
20 - 30V
Pump controller
Defective
test
20-334 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E205
PC400LC-7L
20-335 1
TROUBLESHOOTING
E206
12
E206
SHORT IN TRAVEL SPEED SHIFT SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
Power supply to the travel speed shifting solenoid circuit is switched OFF.
Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
Steps
1.
A.
2.
3.
Specifications
No.
Readings
Solenoid test
20 to 60
Above 1M
Above 1M
(OL) open
(OL) open
0V
20 - 30V
Open or high
resistance
Resistance
B.
Short
to
chassis
ground or within
harness
Resistance
Pump controller
Defective
test
20-336 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E206
12
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L
20-337 1
TROUBLESHOOTING
E211
12
E211
OPEN IN TRAVEL INTERLOCKING SOLENOID
Contents Of Trouble
No current flows to the travel interlocking solenoid circuit, when power is supplied (Pump controller system).
Failure code DW91KA.
None in particular (The solenoid does not function because there is no current).
When the failure cause disappears of itself, the machine operation returns to normal.
Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Error Code E201).
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
3.
Specifications
No.
Readings
Solenoid test
20 to 60
Above 1M
Open or high
resistance
Resistance
Below 1
B.
Short
to
chassis
ground or within
harness
Resistance
Below 1
20 - 60
Pump controller
Defective
test
20-338 1
controller
Voltage
PC400LC-7L
TROUBLESHOOTING
E211
12
Electrical Circuit Diagram for Travel Interlocking Solenoid
PC400LC-7L
20-339 1
TROUBLESHOOTING
E213
12
E213
OPEN IN SWING HOLDING BRAKE SOLENOID
Contents Of Trouble
No current flows to the swing holding brake solenoid circuit, when power is supplied (Pump controller system).
Failure code DW45KA.
None in particular (The solenoid does not function because there is no current).
When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on
machine
The upper structure cannot swing. (The swing holding brake cannot be released.
Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning the swing
holding brake release switch to the RELEASE position.
(In this case, however, the holding brake does not work, when stopping the machine.)
While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in the OFF position.
The controller detects disconnection, when solenoid power is ON. Therefore be sure to check it with power ON after the
repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code E203.)
Relative information
Steps
1.
A.
2.
Specifications
No.
Readings
Solenoid test
20 to 60
Above 1M
3.
Resistance
OFF
Below 1
ON
Above 1M
Continuity one
way only?
Diode test
4.
Diode test
Resistance
Disconnect S25 and X05 connectors from swing lock and park brake switches.
Disconnect C03 and C02 connectors from controller and install T-adapter on C03 and C02 connectors.
B.
Open or high
resistance
Resistance
Below 1
Below 1
Below 1
Below 1
20-340 1
PC400LC-7L
TROUBLESHOOTING
Steps
--5.
E213
---
Voltage
Specifications
No.
Below 1V
10
20 - 60
11
Readings
Pump controller
Disconnect D01 and connect pins (3) and (7) of female side for test.
Defective pump
controller test
Resistance
PC400LC-7L
20-341 1
TROUBLESHOOTING
E214
12
E214
OPEN IN MERGE/DIVIDE SOLENOID
Contents Of Trouble
No current flows to the merge/divide solenoid circuit, when power is supplied (Pump controller system).
Failure code DWJ0KA.
None in particular (The solenoid does not function because there is no current).
When the failure cause disappears of itself, the machine operation returns to normal.
In L mode, speeds of the work equipment and swing in its single operation are too fast.
(F R pumps cannot be disconnected.)
Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Error Code E204).
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
3.
No.
Readings
Merge/divide solenoid
test (Internal short or
ground fault)
20 to 60
Above 1M
Open or high
resistance
Resistance
Below 1
B.
Short
to
chassis
ground or within
harness
Resistance
Below 1
Below 1V
20 - 60
4.
Specifications
Solenoid test
Voltage
Pump controller
Defective
test
20-342 1
controller
Resistance
PC400LC-7L
TROUBLESHOOTING
E214
12
Electrical Circuit Diagram for Merge/Divide Solenoid
PC400LC-7L
20-343 1
TROUBLESHOOTING
E215
12
E215
OPEN IN 2-STAGE RELIEF SOLENOID
Contents Of Trouble
No current flows to the 2-stage relief solenoid circuit, when power is supplied (Pump controller system).
Failure code DWK0KA.
None in particular (The solenoid does not function because there is no current).
When the failure cause disappears of itself, the machine operation returns to normal.
Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Error Code E205).
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
3.
No.
Readings
20 to 60
Above 1M
Open or high
resistance
Resistance
Below 1
B.
Short
to
chassis
ground or within
harness
Resistance
Below 1
Below 1V
20 - 60
4.
Specifications
Solenoid test
Voltage
Pump controller
Defective
test
20-344 1
controller
Resistance
PC400LC-7L
TROUBLESHOOTING
E215
12
Electrical Circuit Diagram for 2-stage Relief Solenoid
PC400LC-7L
20-345 1
TROUBLESHOOTING
E216
12
E216
OPEN IN TRAVEL SPEED SOLENOID
Contents Of Trouble
No current flows to the travel speed solenoid circuit, when power is supplied (Pump controller system).
Failure code DW43KA.
None in particular (The solenoid does not function because there is no current).
When the failure cause disappears of itself, the machine operation returns to normal.
Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
The controller detects disconnection, when solenoid power is ON. BE SURE to check it with power ON after repairs.
(For how to turn power ON or OFF, refer to the troubleshooting under Error Code E206).
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
3.
No.
Readings
20 to 60
Above 1M
Open or high
resistance
Resistance
Below 1
B.
Short
to
chassis
ground or within
harness
Resistance
Below 1
Below 1V
20 - 60
4.
Specifications
Solenoid test
Voltage
Pump controller
Defective
test
20-346 1
controller
Resistance
PC400LC-7L
TROUBLESHOOTING
E216
12
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
PC400LC-7L
20-347 1
TROUBLESHOOTING
E217
12
E217
ABNORMAL INPUT MODEL CODE
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
A model code signal for a model which is not registered in the controller is inputted. (Pump controller system).
Failure code DA2SKQ.
Since the controller controls the machine as PC750/800, the working speed changes and operation becomes difficult.
The model name (number) recognized by the controller can be checked in the monitoring function.
(Code No. 00200: Controller model code.)
Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 02201: Switch input 2.)
Steps
1.
A.
2.
Specifications
No.
Readings
in. 1M
ax. 1
A.
Open or high
resistance
Resistance
ax. 1
ax. 1
ax. 1
ax. 1
ax. 1
in. 1M
3.
4.
Pump controller
A.
A.
Defective
test
20-348 1
controller
Resistance
Voltage
Check wiring harness from C02 (7) to C09 (4) and ground
5 - 30V
Max. 1V
10
PC400LC-7L
TROUBLESHOOTING
E217
12
Electrical circuit diagram related to model selection connector (for pump controller)
PC400LC-7L
20-349 1
TROUBLESHOOTING
E218
12
E218
OPEN IN S-NET COMMUNICATION SIGNAL
The pump controller detected communication failure in the S-NET communication circuit to the monitor panel or
engine controller.
Failure code DA2SKA.
The engine is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears of itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)
Contents Of Trouble
Relative information
Steps
1.
A.
B.
2.
Specifications
No.
Readings
Open or high
resistance
Resistance
Grounding fault
wiring harness
(Contact with
grounding circuit)
of
Resistance
Between P02 (9), (10) monitor panel and CB2 (21), (31)
engine controller
Max. 1
Between P02 (9), (10) monitor panel and C02 (21) pump
controller
Max. 1
Max. 1
Min. 1M
Min. 1M
Min. 1M
Max. 1V
Max. 1V
Max. 1V
6 - 9V
10
6 - 9V
11
A.
Short-circuit (Contact
with 24V circuit)
Voltage
3.
4.
A.
A.
Defective
test
20-350 1
controller
Voltage
Voltage
Between P02 (9), (10) [N/W signal] and (20) [N/W GND]
PC400LC-7L
TROUBLESHOOTING
Steps
5.
E218
Specifications
No.
Readings
Voltage
6 - 9V
12
PC400LC-7L
20-351 1
TROUBLESHOOTING
E222
12
E222
SHORT IN LS-EPC SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast
(The LS valve set pressure cannot be controlled.)
Steps
1.
A.
2.
3.
Specifications
No.
Readings
LS-EPC solenoid
7 - 14
Above 1 M
Above 1 M
(OL) open
(OL) open
(OL) open
7 - 14
Above 1 M
Open or high
resistance
B.
Grounding fault
wiring harness
(Contact with
grounding circuit)
Resistance
of
Resistance
Pump controller
Pump controller
20-352 1
Resistance
PC400LC-7L
TROUBLESHOOTING
E222
PC400LC-7L
20-353 1
TROUBLESHOOTING
E223
12
E223
OPEN IN LS-EPC SOLENOID SYSTEM
Contents Of Trouble
None in particular (The solenoid does not function as there is no current flow to it).
When the failure cause disappears by itself, the machine operation returns to normal.
The travel speed is slow at Mi and Lo or in L mode, speeds of the work equipment and swing are too fast
(The LS valve set pressure cannot be controlled.)
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
Specifications
No.
Readings
LS-EPC solenoid
7 - 14
Above 1 M
3.
Open or high
resistance
Grounding fault
wiring harness
(Contact with 24V
grounding circuit)
Resistance
Below 1
Below 1
Below 1V
of
Voltage
Pump controller
Pump controller
20-354 1
Resistance
7 - 14
PC400LC-7L
TROUBLESHOOTING
E223
PC400LC-7L
20-355 1
TROUBLESHOOTING
E224
12
E224
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL
Contents Of Trouble
Signal voltage from the front pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.)
Failure code DHPAMA.
Phenomenon occurring on
machine
The travel speed does not shift automatically (The travel load pressure cannot be detected).
If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be
Relative information
Steps
1.
2.
supply
Voltage
Specifications
No.
Readings
4.5 - 5.5V
0.5 - 4.5v
The pressure voltage is measured with the wiring harness connected. According, if the voltage is
abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge.
3.
B.
C.
4.
Disconnection
or
defective contact with
connector (Wiring
harness)
Resistance
Resistance
Voltage
Max. 1
Max. 1
Max. 1
Min. 1 MQ
Max. 1V
Max. 1V
4.5 - 5.5V
10
0.5 - 4.5V
11
Pump controller
Ignition switch should be in the ON position or keep the engine running during troubleshooting.
Between C01 (22) and (10)
A. Pump controller test
Voltage
Between C01 (8) and (10)
20-356 1
PC400LC-7L
TROUBLESHOOTING
E224
12
Electrical circuit diagram related to front pump pressure sensor
PC400LC-7L
20-357 1
TROUBLESHOOTING
E225
12
E225
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL
Contents Of Trouble
Signal voltage from the rear pump pressure sensor is below 0.3V or above 4.42V. (Pump controller system.)
Failure code DHPBMA.
Phenomenon occurring on
machine
The travel speed does not shift automatically (The travel load pressure cannot be detected).
If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure sensor will be
Relative information
Steps
1.
2.
supply
Voltage
Specifications
No.
Readings
4.5 - 5.5V
0.5 - 4.5v
The pressure voltage is measured with the wiring harness connected. According, if the voltage is
abnormal, check the wiring harness and controller, too, for another cause of the trouble, then judge.
3.
B.
C.
4.
Disconnection
or
defective contact with
connector (Wiring
harness)
Resistance
Resistance
Voltage
Max. 1
Max. 1
Max. 1
Min. 1 MQ
Max. 1V
Max. 1V
4.5 - 5.5V
10
0.5 - 4.5V
11
Pump controller
Ignition switch should be in the ON position or keep the engine running during troubleshooting.
Between C01 (22) and (10)
A. Pump controller test
Voltage
Between C01 (2) and (10)
20-358 1
PC400LC-7L
TROUBLESHOOTING
E225
12
Electrical circuit diagram related to rear pump pressure sensor
PC400LC-7L
20-359 1
TROUBLESHOOTING
E226
12
E226
ABNORMAL PRESSURE SENSOR POWER SUPPLY
Phenomenon occurring on
machine
Relative information
---
Contents Of Trouble
Steps
1.
A.
2.
No.
Readings
A.
3.
Specifications
Resistance
Min. 1 MQ
Min. 1 MQ
Min. 1 MQ
Min. 1 MQ
4.5 - 5.5V
Pump controller
20-360 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E226
12
Electrical circuit diagram related to pressure sensor power supply
PC400LC-7L
20-361 1
TROUBLESHOOTING
E227
12
E227
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR
Contents Of Trouble
A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Failure code DLE2MA.
Phenomenon occurring on
machine
The machine lacks power a bit. (The engine rotation sensing does not work.)
The engine speed (in the pump controller system) is not monitored on the monitor panel.
Input from the engine rotation sensor (RPM) can be confirmed in the monitor function.
(Code No.: 01006 Engine RPM)
Relative information
Steps
1.
Specifications
No.
Readings
Resistance
adjustment
500 - 1,000
Above 1M
2.
Engine
rotation
improper
3.
Refer to the section Adjusting Engine Rotation Sensor in this manual for inspection and adjustment.
B.
4.
Wiring harness
Disconnection
or
defective contact with
connector
Resistance
Wiring harness
Short (Contact with
24V circuit)
Voltage
Below 1
Below 1
Below 1V
Pump controller
20-362 1
Resistance
500 - 1,000
Above 1M
PC400LC-7L
TROUBLESHOOTING
E227
12
Electrical Circuit Diagram for Engine Rotation Sensor
PC400LC-7L
20-363 1
TROUBLESHOOTING
E228
12
E228
SHORT IN ATTACHMENT RETURN SWITCHING RELAY
Contents Of Trouble
The controller turned OFF power to the attachment return switching relay circuit.
Even when the failure cause disappears by itself, the current does not return to normal.
The hydraulic circuit for attachments is not switched to the single operation circuit.
(The switching valve is not switched to the tank circuit.)
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF).
(Code No.: 02301 Solenoid 2)
This error code detects abnormal on the primary side (coil side) of the attachment return selector relay and cannot detect
abnormality on the secondary side (contact side).
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
No.
Readings
Attachment
return
switching relay test internal short or disconnected
Resistance
100 - 500
Below 1V
20 30V
Below 1V
3.
Specifications
Wiring harness
Short (Contact with
24V circuit)
Voltage
Pump controller
20-364 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E228
12
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L
20-365 1
TROUBLESHOOTING
E232
12
E232
SHORT IN PC-EPC SOLENOID
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
The controller reduces the output to the PC-EPC solenoid circuit to OFF.
Even when the failure cause disappears by itself, the current does not return to normal, unless the engine ignition switch
is turned OFF.
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
(The pump absorption torque cannot be controlled.)
Steps
1.
A.
2.
Readings
7 - 14
Above 1 M
Above 1 M
Above 1 M
Above 1 M
Above 1 M
Emergency
pump
drive switch test internal short or
disconnected
Resistance
Emergency
At S25, between (3) and (4)
pump drive
switch - Normal At S25, between (3) and ground
4.
No.
3.
Specifications
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Pump controller
20-366 1
Resistance
7 - 14
Above 1 M
PC400LC-7L
TROUBLESHOOTING
E232
12
Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L
20-367 1
TROUBLESHOOTING
E233
12
E233
OPEN IN PC-EPC SOLENOID
Contents Of Trouble
None in particular (the solenoid does not function because there is no current flow to it.)
When the failure cause disappears by itself, the current returns to normal.
As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
(The pump absorption torque cannot be controlled.)
Phenomenon occurring on
machine
Relative information
Steps
1.
A.
2.
Specifications
No.
Readings
7 - 14
Above 1 M
3.
Emergency
pump
drive switch test internal short or
disconnected
- Normal
Resistance
- Emergency
Below 1
Above 1 M
Below 1
Above 1 M
Below 1
Below 1
Below 1
Below 1
10
Below 1V
11
Below 1V
12
7 - 14
13
- Normal
- Emergency
Disconnect pump controller C03 and S25 RH console emergency switch and install T-adapters.
B.
4.
Wiring harness
Disconnection
or
defective contact with
connector
Resistance
Wiring harness
Short (Contact with
24V circuit)
Voltage
Pump controller
20-368 1
Resistance
PC400LC-7L
TROUBLESHOOTING
E233
12
Electrical Circuit Diagram for PC-EPC Solenoid
PC400LC-7L
20-369 1
TROUBLESHOOTING
E238
12
E238
OPEN IN ATTACHMENT RETURN SWITCHING RELAY
When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24V voltage is not
generated. (Pump controller system)
Failure code D196KA.
None in particular.
When the failure cause disappears by itself, the current returns to normal.
The hydraulic circuit for attachments cannot be switched to the single operation.
(The switching valve cannot be switched to the tank circuit.)
It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON or OFF).
(Code No.: 02301 Solenoid 2)
This code detects abnormality on the primary side (coil side) of the attachment return selector relay and cannot detect
abnormality on the secondary side (contact side).
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Relative information
Steps
1.
2.
3.
No.
Readings
Resistance
100 - 500
Below 1
Below 1
Above 1
Above 1
20 - 30V
Below 1V
B.
4.
Attachment
return
switching relay test internal short or
disconnected
Specifications
If fuse No. 2 has been blown, there is a big possibility that a grounding fault occurred in the relay circuit. (See Step 3B)
Wiring harness
Disconnection
or
defective contact with
connector
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Pump controller
Voltage
Other than B
mode
B mode
20-370 1
PC400LC-7L
TROUBLESHOOTING
E238
12
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
PC400LC-7L
20-371 1
TROUBLESHOOTING
E245
12
E245
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Short in attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system)
Failure code DXE4KB.
The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF.
Even when the failure cause disappears, the EPC solenoid circuit does not return to normal, unless the engine ignition
switch is turned OFF.
The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting
EPC solenoid circuit.
(Code No.: 01700 Service solenoid current)
Relative information
Steps
1.
A.
2.
No.
Readings
7 - 14
Above 1
Above 1
3.
Specifications
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Pump controller
20-372 1
Resistance
7 - 14
Above 1
PC400LC-7L
TROUBLESHOOTING
E245
12
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L
20-373 1
TROUBLESHOOTING
E246
12
E246
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM
Contents Of Trouble
No current flow to the attachment oil flow rate adjusting EPC solenoid circuit. (Pump controller system)
Failure code DXE4KA.
None in particular (The solenoid does not work, as there is no current flowing to it.)
If the failure cause disappears, the EPC solenoid circuit returns to normal by itself.
Phenomenon occurring on
machine
The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow rate adjusting
EPC solenoid circuit.
(Code No.: 01700 Service solenoid current)
Relative information
Steps
1.
A.
2.
Specifications
No.
Readings
7 - 14
Above 1
Below 1
Between C03 (3), (13), (23) and V30 (2) and grounding
Below 1
Below 1V
7 - 14
B.
3.
Resistance
Wiring harness
Short (Contact with
24V circuit)
Voltage
Pump controller
20-374 1
Resistance
PC400LC-7L
TROUBLESHOOTING
E246
12
Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
PC400LC-7L
20-375 1
TROUBLESHOOTING
E247
12
E247
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR
Contents Of Trouble
Signal voltage from the arm IN PPC pressure sensor is below 0.3V or above 4.42V.
Failure code DHS3MA.
The controller sets the arm IN PPC pressure to 0 kg/cm2 (0 psi) for control.
If the failure cause disappears by itself, the machine operation returns to normal.
If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The arm IN PPC circuit
pressure cannot be detected).
Phenomenon occurring on
machine
If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be
Relative information
Steps
1.
2.
3.
Specifications
No.
Readings
Voltage
4.5 5.5V
0.5 4.5V
Max. 1
Max. 1
Max. 1
Min. 1M
Max. 1V
Max. 1V
4.5 5.5V
0.5 4.5V
10
B.
C.
4.
Resistance
Resistance
Voltage
Pump controller
Ignition switch should remain in the ON position or keep the engine running during troubleshooting.
At C01, between (22) and (10)
A. Pump controller test
Voltage
At C01, between (19) and (10)
20-376 1
PC400LC-7L
TROUBLESHOOTING
E247
12
Circuit diagram related to arm IN PPC pressure sensor
PC400LC-7L
20-377 1
TROUBLESHOOTING
E248
12
E248
ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR
Contents Of Trouble
Signal voltage from the bucket CURL PPC pressure sensor is below 0.3V or above 4.42V.
Failure code DHS4MA.
The controller sets the bucket CURL PPC pressure to 0 kg/cm2 (0 psi) for control.
If the failure cause disappears by itself, the machine operation returns to normal.
If auto deceleration is operated, auto deceleration cannot be released when moving the bucket CURL (The bucket
CURL PPC circuit pressure cannot be detected).
Phenomenon occurring on
machine
If the 5V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure sensor will be
Relative information
Steps
1.
2.
Specifications
No.
Readings
Voltage
4.5 5.5V
0.5 4.5V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then
judge.
3.
B.
C.
4.
Resistance
Resistance
Voltage
Max. 1
Max. 1
Max. 1
Min. 1M
Max. 1V
Max. 1V
Pump controller
Ignition switch should remain in the ON position or keep the engine running during troubleshooting.
At C01, between (22) and (10)
A. Pump controller test
Voltage
At C01, between (19) and (10)
20-378 1
4.5 5.5V
0.5 4.5V
10
PC400LC-7L
TROUBLESHOOTING
E248
12
Circuit diagram related to bucket CURL PPC pressure sensor
PC400LC-7L
20-379 1
TROUBLESHOOTING
E257
12
E257
ABNORMALITY IN PUMP
The pump controller detected communication failure in the CAN communication circuit to the monitor panel or engine
controller.
Failure code DA2RMC.
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
If the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Relative information
---
Contents Of Trouble
Steps
1.
Specifications
No.
Readings
B.
Resistance
C.
2.
Below 1
Below 1
Below 1
Below 1
Above 1M
Above 1M
Above 1M
Above 1M
Above 1M
Above 1M
10
Below 1V
11
Below 1V
12
Below 1V
13
Below 1V
14
Below 1V
15
Below 1V
16
40 - 80
17
40 - 80
18
3.
Resistance
If 1 - 2 are not detected, monitor panel, engine controller or pump controller may be defective. (Since trouble is in those devices, troubleshooting
cannot be carried out.)
20-380 1
PC400LC-7L
TROUBLESHOOTING
E257
12
Electrical circuit diagram related to CAN communication
PC400LC-7L
20-381 1
TROUBLESHOOTING
E315
12
E315
SHORT IN BATTERY RELAY SYSTEM
Contents Of Trouble
The controller turns OFF the output to the battery relay drive circuit.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
There may be a trouble in writing data into ROM (non-volatile memory) of each controller.
Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
(Code No.: 03700 Controller output 1)
Relative information
Steps
1.
A.
2.
Readings
Resistance
Approximately
100
Min. 1M
Continuity one
way only?
Yes or No
Continuity one
way only?
Yes or No
Min. 1M
Min. 1M
Min. 1M
20 - 30V
(for 0.5 sec.)
At battery relay
unit
Between BR and E
Between BR and grounding
Diode test
Resistance
4.
No.
Diode
3.
Specifications
Battery relay
Hold the ignition switch in the OFF position during the troubleshooting.
Resistance
Pump controller
Pump controller
20-382 1
Voltage
Ignition switch
ON OFF
PC400LC-7L
TROUBLESHOOTING
E315
12
Electrical circuit diagram related to battery relay drive
PC400LC-7L
20-383 1
TROUBLESHOOTING
E91B
12
E91B
ENGNE NE SENSOR PROBLEM
Contents Of Trouble
Cranking angle cannot be judged from engine Ne speed sensor signal. (Engine controller system)
Failure code DLE3LC.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above lower idling.
Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
(Code No.: 01002 Engine speed)
Relative information
Steps
1.
A.
2.
No.
Readings
Engine Ne speed
sensor test - internal
short or disconnected
85 - 210
Above 1
Below 1
Below 1
Above 1
Above 1
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Engine controller
20-384 1
Resistance
85 - 210
Above 1
PC400LC-7L
TROUBLESHOOTING
E91B
12
Electrical circuit diagram related to engine Ne speed sensor
PC400LC-7L
20-385 1
TROUBLESHOOTING
E91C
12
E91C
ENGINE G SENSOR PROBLEM
Contents Of Trouble
Cylinder cannot be judged from the engine G speed sensor signal. (Engine controller system)
Failure code DLH1LC.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above lower idling.
Relative information
Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
Steps
1.
A.
2.
No.
Readings
Engine G speed
sensor test - internal
short or disconnected
Resistance
1.4 - 3.5k
Above 1
Below 1
Below 1
Above 1
Above 1
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Engine controller
20-386 1
Resistance
1.4 - 3.5k
Above 1
Above 1
PC400LC-7L
TROUBLESHOOTING
E91C
12
Electrical circuit diagram related to engine G speed sensor
PC400LC-7L
20-387 1
TROUBLESHOOTING
E920
12
E920
ENGINE TYPE SELECTION ERROR
Contents Of Trouble
Relative information
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above lower idling.
The model name (figure) recognized by the controller can be checked in the monitoring function.
(Code No.: 00201 Controller model code)
Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Coed No.: 17400 Engine controller input state)
Steps
1.
No.
Readings
Model selection
connector test internal short or
disconnected
Resistance
Above 1
Above 1
Above 1
Above 1
Above 1
Above 1
Below 1
Below 1
Below 1
Above 1
10
Above 1
11
20 30V
12
20 30V
13
Below 1V
14
B.
3.
Specifications
A.
2.
The model selection signal directly taken by the engine controller does not conform to the model in the controller or is
not confirmed. (Engine controller system)
Failure code DB29KQ.
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Engine controller
20-388 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E920
12
Electrical circuit diagram related to model selection connector (for engine controller)
PC400LC-7L
20-389 1
TROUBLESHOOTING
E921
12
E921
ENGINE TYPE MISMATCH
Contents Of Trouble
Relative information
The model information taken by the engine controller through the model selection connector does not conform to the
model information taken from the pump controller by communication. (Engine controller system)
Failure code DB20KQ.
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above lower idling.
The model name (figure) recognized by the controller can be checked in the monitoring function.
(Code No.: 00201 Controller model code)
The model name (figure) recognized by the pump controller can be checked in the monitoring function.
(Code No.: 00200 Controller model code)
Steps
Specifications
No.
Readings
1.
2.
Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be
carried out.)
3.
Pump controller may be defective. (Since trouble is in the controller, troubleshooting cannot be
carried out.)
20-390 1
PC400LC-7L
TROUBLESHOOTING
E921
12
MEMORANDUM
PC400LC-7L
20-391 1
TROUBLESHOOTING
E931
12
E931
FUEL DIAL SYSTEM ERROR
Contents Of Trouble
Phenomenon occurring on
machine
Relative information
The signal voltage from the fuel control dial is below 0.3V or above 4.5V. (Engine controller system)
Failure code DK10KX.
If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or 100% after the
engine is started.
If the abnormality is detected while the engine is running, the fuel control dial signal just before the abnormality is
detected is kept.
When the failure cause disappears by itself, the machine operation returns to normal.
Input from the fuel control dial (voltage) can be checked in the monitoring function.
(Code No.: 03000 Fuel control dial voltage)
Steps
1.
A.
2.
Specifications
No.
Readings
Resistance
4.0 6.0k
0.25 7.0k
0.25 7.0k
B.
C.
3.
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Wiring harness
Contact with 24V
circuit
Voltage
Below 1
Below 1
Below 1
Below 1
Above 1
Above 1
Below 1V
10
Below 1V
11
4.6 - 5.4V
12
4.6 - 5.4V
13
0.3 - 4.5V
14
0.3 - 4.5V
15
Engine controller
A.
20-392 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E931
PC400LC-7L
20-393 1
TROUBLESHOOTING
E934
12
E934
ENGINE COOLANT SENSOR HI ERROR
The signal voltage from the engine water high temperature sensor is below 0.5V or above 4.5V. (Engine controller
system)
Failure code DGE2KX.
The signal of the engine water high temperature sensor is kept at 90C.
When the failure cause disappears, the machine operation returns to normal.
Phenomenon occurring on
machine
The engine does not start easily when the temperature is low.
The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.
Input from the engine high temperature sensor (voltage and water temperature) can be checked in the monitoring
function.
(Code No.: 04106 Engine water temperature sensor Hi,
Code No.: 04102 Engine water temperature (High temperature))
Contents Of Trouble
Relative information
Steps
1.
A.
2.
No.
Readings
Resistance
3.5 90k
Above 1
Above 1
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Below 1
Below 1
Below 1
Above 1
Engine controller
A.
20-394 1
Resistance
3.5k - 90k
3.5k - 90k
Above 1
10
Above 1
11
Above 1
12
PC400LC-7L
TROUBLESHOOTING
E934
12
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
PC400LC-7L
20-395 1
TROUBLESHOOTING
E96A
12
E96A
ENGINE COOLANT SENSOR LO ERROR
Contents Of Trouble
The signal voltage from the engine water low temperature sensor is above 4.5V. (Engine controller system)
Failure code DGE3L6.
The signal of the engine water low temperature sensor is kept at 20C. (If the signal of the high temperature sensor is
effective, it is used as a substitute.)
When the failure cause disappears, the machine operation returns to normal.
The engine does not start easily when the temperature is low.
The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.
Input from the engine low temperature sensor (voltage and water temperature) can be checked in the monitoring
function.
(Code No.: 04105 Engine water temperature sensor Lo,
Code No.: 04107 Engine water temperature (Low temperature))
Relative information
Steps
1.
A.
2.
No.
Readings
0.3 9k
Above 1
Above 1
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Below 1
Below 1
Below 1
Above 1
0.3 9k
0.3 9k
Above 1
10
Above 1
11
Above 1
12
Engine controller
A.
20-396 1
Resistance
PC400LC-7L
TROUBLESHOOTING
E96A
12
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
PC400LC-7L
20-397 1
TROUBLESHOOTING
E936
12
E936
ENGINE OIL PRESSURE SWITCH ERROR
The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of the
high-pressure switch is opened (disconnected from grounding) while the engine is running.
The signal circuit of the low-pressure switch is opened (disconnected from ground) while the engine is stopped (the
starting signal is OFF).
The signal circuit of the high-pressure switch is opened (disconnected from ground) while the engine is stopped (the
starting signal is OFF).
Failure code DDE2L6.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
The engine does not start easily when the temperature is low.
The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.
Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring function.
(Code No.: 17400 Engine controller input)
Contents Of Trouble
Relative information
Steps
1.
A.
B.
2.
No.
Readings
Engine
Resistance
PSL
Below 1
Above 1
Below 1
Above 1
Below 1
Below 1
Above 1
Above 1
Stopped
Low idling
Engine
Resistance
PSH
Stopped
Running at 1,300 Between terminal and grounding
rpm or higher
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Engine controller
---
20-398 1
Voltage
CB1
Between (21) and ground (Low
pressure switch signal)
Below 1V
20 - 30V
10
Stopped
Between (21) and ground (Low
Running at 1,300 pressure switch signal)
rpm or higher
Below 1V
11
20 - 30V
12
Low idling
Carry out troubleshooting while the engine is running 15 seconds after the engine is started.
PC400LC-7L
TROUBLESHOOTING
E936
12
Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
PC400LC-7L
20-399 1
TROUBLESHOOTING
E93C
12
E93C
ENGINE BOOST SENSOR ERROR
Contents Of Trouble
The signal voltage from the boost pressure sensor is below 0.3V or above 4.7V.
Failure code DH30KX.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above idling.
Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36501 Boost pressure sensor voltage,
(Code No.: 36500 Boost pressure)
Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.
Relative information
Steps
1.
A.
2.
Specifications
No.
Readings
PIM
Voltage
Power supply
4.6 5.4V
Signal
0.5 - 4.5V
Below 1
Below 1
Below 1
Below 1
B.
C.
3.
Resistance
Resistance
Voltage
Above 1
Above 1
Above 1
Below 1V
10
Below 1V
11
Below 1V
12
4.6 - 5.4V
13
4.6 - 5.4V
14
0.3 - 4.7V
15
0.3 - 4.7V
16
Engine controller
A.
20-400 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E93C
12
Electrical circuit diagram related to boost pressure sensor
PC400LC-7L
20-401 1
TROUBLESHOOTING
E93D
12
E93D
ENGINE FUEL TEMPERATURE SENSOR ERROR
Contents Of Trouble
The signal voltage from the fuel temperature sensor is above 4.5V.
Failure code DGE4KX.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
(Code No.: 14201 Fuel temperature sensor voltage)
Relative information
Steps
1.
A.
2.
No.
Readings
Fuel temperature
sensor test - internal
short or disconnected
0.3k - 9k
Above 1
Above 1
Below 1
Below 1
Below 1
Above 1
B.
3.
Specifications
Resistance
Wiring harness
Short (Contact with
grounding circuit)
Resistance
Engine controller
A.
20-402 1
Resistance
0.3k - 9k
0.3k - 9k
Above 1
10
Above 1
11
PC400LC-7L
TROUBLESHOOTING
E93D
12
Electrical circuit diagram related to fuel temperature sensor
PC400LC-7L
20-403 1
TROUBLESHOOTING
E953
12
E953
ENGINE COMMUNICATION ABNORMALITY
The engine controller detected communication failure in the CAN communication circuit to the monitor panel or pump
controller.
Failure code DB2RMC.
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Relative information
---
Contents Of Trouble
Steps
1.
Specifications
No.
Readings
B.
C.
2.
Wiring harness
Short (Contact with
grounding circuit)
Wiring harness
Contact with 24V
circuit
Resistance
Resistance
Voltage
Below 1
Below 1
Below 1
Below 1
Above 1
Above 1
Above 1
Above 1
Above 1
Above 1
10
Below 1V
11
Below 1V
12
Below 1V
13
Below 1V
14
Below 1V
15
Below 1V
16
3.
Resistance
20-404 1
40 - 80
17
40 - 80
18
If causes 1A, 1B, 1C are not detected, monitor panel, engine controller or pump controller may be
defective. (Since trouble is in those devices, troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E953
12
Electrical circuit diagram related to CAN communication
PC400LC-7L
20-405 1
TROUBLESHOOTING
E954
12
E954
SHORT IN ENGINE IGNITION SWITCH
Contents Of Trouble
Ignition switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Failure code DD11KB.
Phenomenon occurring on
machine
Input from ignition switch signal C (ON or OFF) can be checked in the monitoring function.
(Code No.: 17400 Engine controller input)
Relative information
Steps
1.
A.
2.
No.
Readings
Ignition switch
Resistance
Above 1
Below 1
Below 1V
Below 1V
Below 1V
Below 1V
Below 1V
Below 1V
Between
terminal B and terminal C
OFF
START
A.
3.
Specifications
Voltage
Engine controller
20-406 1
Voltage
CB1
Ignition switch
--Below 1V
PC400LC-7L
TROUBLESHOOTING
E954
12
Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L
20-407 1
TROUBLESHOOTING
E955
12
E955
ENGINE S-NET ERROR
The engine controller detected communication failure in the S-NET communication circuit to the monitor panel or
pump controller (Engine controller system).
Failure code DB2SMC.
The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No.: 05100 Connection of S-NET)
Contents Of Trouble
Relative information
Steps
1.
Specifications
No.
Readings
B.
C.
2.
Wiring harness
Short (Contact with
grounding circuit)
Wiring harness
Contact with 24V
circuit
Resistance
Below 1
Below 1
Below 1
Resistance
Voltage
Above 1
Above 1
Above 1
Above 1
Above 1
Above 1
Below 1V
10
Below 1V
11
Below 1V
12
Below 1V
13
Below 1V
14
Below 1V
15
6 - 9V
16
6 - 9V
17
6 - 9V
18
6 - 9V
19
Monitor panel
3.
Voltage
Engine controller
20-408 1
Voltage
PC400LC-7L
TROUBLESHOOTING
Steps
4.
E955
Specifications
No.
Readings
Pump controller
Voltage
6 - 9V
20
PC400LC-7L
20-409 1
TROUBLESHOOTING
E956
12
E956
ENGINE POWER FAILURE (1)
Contents Of Trouble
When the ignition switch is turned ON, the source voltage of the controller is below 10V. (Engine controller system)
Failure code DB22KK.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Relative information
---
Steps
Specifications
1.
Circuit breaker 7 defective If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 3B.)
2.
3.
---
Readings
Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is
defective.
A.
B.
4.
Engine
controller
power supply relay test
- internal short or
disconnected
No.
Resistance
Resistance
Below 1
Below 1
Below 1
Below 1
Between R22 (1) and H15 (5) and CB1 (13), (19)
Below 1
Between R22 (2) and CB1 (7), (8) and CB2 (11) and A10
ground
Below 1
Above 1M
Above 1M
Above 1M
Above 1M
10
Above 1M
11
Engine controller
20-410 1
Voltage
Ignition switch
---
OFF
Below 1V
12
ON
20 - 30V
13
PC400LC-7L
TROUBLESHOOTING
E956
12
Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-411 1
TROUBLESHOOTING
E957
12
E957
ENGINE POWER FAILURE (2)
Contents Of Trouble
When the ignition switch is turned OFF, the source voltage of the controller is above 10V. (Engine controller system)
Failure code D1D0KB.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Relative information
---
Steps
1.
A.
2.
No.
Readings
Engine
controller
power supply relay test
- internal short or
disconnected
---
Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is
defective.
3.
Specifications
Voltage
Between CB3 (1), (2), (21) and R22 (3) and ground
Below 1V
Below 1V
Engine controller
20-412 1
Voltage
Ignition switch
---
OFF
Below 1V
ON
20 - 30V
PC400LC-7L
TROUBLESHOOTING
E957
12
Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-413 1
TROUBLESHOOTING
E95A
12
E95A
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR
Contents Of Trouble
The fuel injection adjustment switch of the controller is not set to the correct position. (Engine controller system)
Failure code DB2AMA.
None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.
Phenomenon occurring on
machine
Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring function.
(Code No.: 36800 Right fuel injection amount adjustment switch
Code No.: Left fuel injection amount adjustment switch)
Relative information
Steps
Specifications
No.
Readings
1.
2.
20-414 1
PC400LC-7L
TROUBLESHOOTING
E95A
12
MEMORANDUM
PC400LC-7L
20-415 1
TROUBLESHOOTING
E970
12
E970
PCV1 OVER CURRENT
Abnormal current flowed in the fuel supply pump PCV1 circuit. (Engine controller system)
Failure code AD11KB.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
Specifications
No.
Readings
2.3 - 5.3
Above 1
Above 1
Below 1V
Below 1V
B.
3.
Resistance
Voltage
Engine controller
20-416 1
Resistance
2.3 - 5.3
Above 1
PC400LC-7L
TROUBLESHOOTING
E970
PC400LC-7L
20-417 1
TROUBLESHOOTING
E971
12
E971
PCV2 OVER CURRENT
Abnormal current flowed in the fuel supply pump PCV2 circuit. (Engine controller system)
Failure code AD51KB.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
Specifications
No.
Readings
2.3 - 5.3
Above 1
Above 1
Below 1V
Below 1V
B.
3.
Resistance
Voltage
Engine controller
20-418 1
Resistance
2.3 - 5.3
Above 1
PC400LC-7L
TROUBLESHOOTING
E971
12
Electrical circuit diagram related to fuel supply pump PCV2
PC400LC-7L
20-419 1
TROUBLESHOOTING
E974
12
E974
PCV1 LINE CUT
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
2.3 - 5.3
Above 1
Below 1
Below 1
Above 1
B.
3.
Specifications
Resistance
Resistance
Engine controller
20-420 1
Resistance
2.3 - 5.3
Above 1
PC400LC-7L
TROUBLESHOOTING
E974
12
Electrical circuit diagram related to fuel supply pump PCV1
PC400LC-7L
20-421 1
TROUBLESHOOTING
E975
12
E975
PCV2 LINE CUT
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
2.3 - 5.3
Above 1
Below 1
Below 1
Above 1
B.
3.
Specifications
Resistance
Resistance
Engine controller
20-422 1
Resistance
2.3 - 5.3
Above 1
PC400LC-7L
TROUBLESHOOTING
E975
12
Electrical circuit diagram related to fuel supply pump PCV2
PC400LC-7L
20-423 1
TROUBLESHOOTING
E977
12
E977
RAIL PRESSURE SENSOR ERROR
Contents Of Trouble
The signal voltage from the common rail fuel pressure sensor is below 0.7V or above 4.5V. (Engine controller system)
Failure code DH40KX.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.
Relative information
Steps
1.
A.
2.
No.
Readings
Voltage
4.6 - 5.4V
0.7 - 4.5V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the
voltage is abnormal, check the wiring harness and controller for another cause of the trouble and then
judge.
B.
C.
3.
Specifications
Resistance
Resistance
Voltage
Below 1
Below 1
Below 1
Above 1
Above 1
Above 1
Below 1V
Below 1V
10
Below 1V
11
4.6 - 5.4V
12
0.7 - 4.5V
13
Engine controller
20-424 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E977
12
Electrical circuit diagram related to common rail fuel pressure sensor
PC400LC-7L
20-425 1
TROUBLESHOOTING
E979
12
E979
RAIL PRESSURE HIGH
The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1). (Engine controller
system)
Failure code AD00L2.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Contents Of Trouble
Relative information
Steps
Cause
1.
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2.
3.
4.
5.
The overflow valve may have trouble of breakage of spring, wear of seat or fixing of ball. Check it
directly.
6.
7.
20-426 1
PC400LC-7L
TROUBLESHOOTING
E97A
12
E97A
RAIL PRESSURE ABNORMAL HIGH
Contents Of Trouble
The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2). (Engine controller system)
Failure code AD00MA.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Relative information
Steps
1.
Cause
Common rail related device defective
PC400LC-7L
20-427 1
TROUBLESHOOTING
E97B
12
E97B
RAIL PRESSURE LOW
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
No pressure feed by fuel supply pump (level 1) occurred. (Engine controller system)
Failure code AD10L3.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Relative information
Steps
Cause
1.
If any other error code or failure code is displayed, carry out troubleshooting for it first.
2.
3.
A low pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.
4.
The fuel filter /strainer may be clogged. Referring to Note 2, carry out troubleshooting.
5.
6.
7.
Common rail fuel pressure sensor defective The common rail fuel pressure sensor may be defective. Check it directly.
8.
9.
Note 1: Check the low-pressure circuit devices for the following points.
1.
Insufficiency of fuel.
2.
3.
4.
Malfunction of bypass valve and installation of wrong part (See Fig. 1).
5.
6.
20-428 1
PC400LC-7L
TROUBLESHOOTING
E97B
12
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
Overflow valve (1): Spring is seen through both holes.
Bypass valve (2): Spring is seen through hole on nut side.
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1.
2.
3.
Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it.
Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too.
Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
Note 3: Judge the condition of the fuel injector by measuring the fuel spill rate.
WARNING! When performing the follow work, take care not to scald yourself with the fuel which
becomes hot (up to 90C).
1.
2.
Disconnect the hose connected to the centralized return spill tube adapters (at the rear of the engine).
Connect another hose to the spill tube end so that spill fuel can be received in a container.
3.
Run the engine and stall at each speed (relieve the arm circuit by moving the arm in). Measure the quantity of the fuel
spilling in 1 minute under this condition.
Limit of spill of fuel (Total of spill from 6 cylinders.
Stall speed (rpm)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
PC400LC-7L
20-429 1
TROUBLESHOOTING
E97C
12
E97C
RAIL PRESSURE TOO LOW
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
No pressure feed by fuel supply pump (level 2) occurred. (Engine controller system)
Failure code AD10MB.
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Relative information
Steps
1.
Cause
Common rail related device defective
20-430 1
PC400LC-7L
TROUBLESHOOTING
E97D
12
E97D
RAIL PRESSURE OUT OF CONTROL
Contents Of Trouble
Response from controller
Phenomenon occurring on
machine
Abnormal fuel pressure was generated in the common rail. (Engine controller system)
Failure code AD10MA.
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring function.
(Code No.: 36401 Common rail pressure sensor voltage
Code No.: 36400 Common rail fuel pressure)
Relative information
Steps
1.
Cause
Common rail related device defective
PC400LC-7L
20-431 1
TROUBLESHOOTING
E980
12
E980
ENGINE CONTROLLER ABNORMALITY
The machine is driven with limited output or all output is turned OFF.
Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
Specifications
No.
Readings
20-432 1
Resistance
Below 1
Below 1
Below 1
PC400LC-7L
TROUBLESHOOTING
E980
12
Electrical circuit diagram related to engine controller power supply
PC400LC-7L
20-433 1
TROUBLESHOOTING
E981
12
E981
FUEL INJECTOR 1 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
20-434 1
PC400LC-7L
TROUBLESHOOTING
E982
12
E982
FUEL INJECTOR 2 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
PC400LC-7L
20-435 1
TROUBLESHOOTING
E983
12
E983
FUEL INJECTOR 3 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
20-436 1
PC400LC-7L
TROUBLESHOOTING
E984
12
E984
FUEL INJECTOR 4 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
PC400LC-7L
20-437 1
TROUBLESHOOTING
E985
12
E985
FUEL INJECTOR 5 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
20-438 1
PC400LC-7L
TROUBLESHOOTING
E986
12
E986
FUEL INJECTOR 6 DISCONNECTION
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Contents Of Trouble
Response from controller
Steps
1.
A.
2.
No.
Readings
Resistance
0.4 - 1.1
Below 1
Below 1
0.4 - 1.1
3.
Specifications
Resistance
Engine controller
Resistance
PC400LC-7L
20-439 1
TROUBLESHOOTING
E98A
12
E98A
FUEL INJECTOR 1 - 3 S/C
Contents Of Trouble
Abnormal current in the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit. (Engine controller
system)
Failure code ADAZKB.
Power to the fuel injector 1 circuit, fuel injector 2 circuit and fuel injector 3 circuit is switched OFF
Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Steps
1.
A.
2.
Readings
0.4 - 1.1
Above 1M
0.4 - 1.1
Above 1M
0.4 - 1.1
Above 1M
4.
No.
3.
Specifications
A.
20-440 1
Resistance
Above 1M
Above 1M
Above 1M
Above 1M
10
Above 1M
11
Above 1M
12
PC400LC-7L
TROUBLESHOOTING
Steps
5.
Specifications
No.
Below 1V
13
Below 1V
14
Below 1V
15
Below 1V
16
Below 1V
17
Below 1V
18
0.4 - 1.1
19
0.4 - 1.1
20
0.4 - 1.1
21
Above 1M
22
Above 1M
23
Above 1M
24
Above 1M
25
Above 1M
26
Above 1M
27
Readings
A.
6.
E98A
Voltage
Engine controller
A.
Resistance
PC400LC-7L
20-441 1
TROUBLESHOOTING
E98B
12
E98B
FUEL INJECTOR 4 - 6 S/C
Contents Of Trouble
Abnormal current in the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit. (Engine controller
system)
Failure code ADDZKB.
Power to the fuel injector 4 circuit, fuel injector 5 circuit and fuel injector 6 circuit is switched OFF
Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.
Phenomenon occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling.
The engine stops and it cannot be started (when user code E10 is displayed).
Relative information
---
Steps
1.
A.
2.
Readings
0.4 - 1.1
Above 1M
0.4 - 1.1
Above 1M
0.4 - 1.1
Above 1M
4.
No.
3.
Specifications
A.
20-442 1
Resistance
Above 1M
Above 1M
Above 1M
Above 1M
10
Above 1M
11
Above 1M
12
PC400LC-7L
TROUBLESHOOTING
Steps
5.
Specifications
No.
Below 1V
13
Below 1V
14
Below 1V
15
Below 1V
16
Below 1V
17
Below 1V
18
0.4 - 1.1
19
0.4 - 1.1
20
0.4 - 1.1
21
Above 1M
22
Above 1M
23
Above 1M
24
Above 1M
25
Above 1M
26
Above 1M
27
Readings
A.
6.
E98B
Voltage
Engine controller
A.
Resistance
PC400LC-7L
20-443 1
TROUBLESHOOTING
A000N1
12
A000N1
ENGINE HIGH IDLING SPEED OUT OF STANDARD
User Code
Error Code
Failure Code
E22
E922
A000N1
Failure
phenomenon
Failure content
While the engine is running, its speed above 2,350 rpm is detected.
Response from
controller
None in particular.
Phenomenon occurring
on machine
Relative information
Step
1.
Cause
Check for an external or an internal factor which heightens the engine high idling speed and then
Overrun of engine (While system is normal)
check the mechanical system of the engine.
2.
3.
Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
A.
20-444 1
Engine speed
Engine
High idling
Monitoring
01006 Engine speed
1,880 1,980
rpm
PC400LC-7L
TROUBLESHOOTING
A000N2
12
A000N2
ENGINE LOW IDLING SPEED OUT OF STANDARD
User Code
Error Code
Failure Code
---
---
A000N2
Failure
phenomenon
Failure content
While the engine is running, its speed below 500 rpm is detected.
Response from
controller
None in particular.
When the failure cause disappears by itself, the machine returns to normal.
Phenomenon occurring
on machine
Relative information
Step
Cause
Check for an external or an internal factor which heightens the engine low idling speed and then
check the mechanical system of the engine.
2.
3.
Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
1.
A.
PC400LC-7L
Engine speed
Engine
Low idling
Monitoring
01006 Engine speed
20-445 1
TROUBLESHOOTING
AA10NX
12
AA10NX
AIR CLEANER CLOGGED
The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine is running.
(Mechanical system)
Failure code AA10NX.
None in particular.
Phenomenon occurring on
machine
If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this failure code is
recorded.
Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code No.: 04501 Monitor input 1)
Contents Of Trouble
Relative information
Steps
1.
2.
3.
Resistance
No.
Below 1
Above 1M
Below 1
Below 1
Below 1V
20 - 30V
Readings
4.
Specifications
Resistance
Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
A.
20-446 1
Voltage
PC400LC-7L
TROUBLESHOOTING
AA10NX
12
Electrical circuit diagram related to air cleaner clogging switch
PC400LC-7L
20-447 1
TROUBLESHOOTING
AB00KE
12
AB00KE
CHARGE VOLTAGE LOW
Contents Of Trouble
Signal voltage from alternator is below 20V while the engine is running. (Mechanical system)
Failure code AB00KE.
None in particular.
Phenomenon occurring on
machine
If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure code is
recorded.
Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No.: 04300 Charge voltage
Code No.: 04501 Monitor input 2)
Relative information
Steps
1.
Readings
Above 20V
Below 1
Resistance
4.
No.
3.
Specifications
Alternator defective
2.
Resistance
Above 1M
Above 1M
Above 1M
Above 20V
Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
A.
20-448 1
Voltage
PC400LC-7L
TROUBLESHOOTING
AB00KE
12
Electrical circuit diagram related to engine preheating, starting, charging
PC400LC-7L
20-449 1
TROUBLESHOOTING
B@BAZG
12
B@BAZG
ENGINE OIL PRESSURE LOW
The signal circuit of the low pressure switch is closed (connected to ground) and the signal circuit of the high pressure
switch is closed (connected to ground) while the engine speed is above 600 rpm.
The signal circuit of the low pressure switch is opened (disconnected from ground) and the signal circuit of the high
pressure switch is closed (connected to ground) while the engine speed is above 1,300 rpm. (Mechanical system)
Failure code B@BAZG.
None in particular.
Phenomenon occurring on
machine
When this failure occurs, the error code is displayed only when the user code is turned ON and the failure code is
recorded in only the mechanical system of the failure history.
If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this failure code is
recorded.
Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.
(Code No.: 17400 Engine controller input)
Contents Of Trouble
Relative information
Steps
Specifications
No.
Readings
1.
Engine oil pressure lowered (While system is Check the engine oil pressure. If it is abnormal, find out the cause and check the engine for damage, if
normal)
need be, repair it.
2.
3.
Engine controller
Hold ignition switch in the ON position or start engine during the troubleshooting.
Engine
Stopped
A.
Voltage
Low idling
Stopped
Above 1,300
rpm
20-450 1
CB1
Between (21) and grounding (Low
pressure switch signal)
Between (15) and grounding (High
pressure switch signal)
Below 1V
20 - 30V
Below 1V
20 - 30V
PC400LC-7L
B@BAZG
12
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
PC400LC-7L
20-451
B@BAZK
12
B@BAZK
ENGINE OIL LEVEL LOW
The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the engine is stopped.
(Mechanical system)
Failure code B@BAZK.
None in particular.
Phenomenon occurring on
machine
If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this failure code is
recorded.
Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.
(Code No.: 04501 Monitor input 2)
Contents Of Trouble
Relative information
Steps
1.
2.
3.
No.
Readings
Normal level
Below normal level
OL
--Below 1
Above 1M
Below 1
Below 1V
20 - 30V
Wiring harness
4.
Specifications
Check the engine oil level in the engine oil pan. If it is low, add oil. (If it is reduced frequently find out
the cause.)
Resistance
Monitor panel
Hold ignition switch in the ON position or start engine during the troubleshooting.
A.
20-452
Voltage
PC400LC-7L
B@BAZK
12
Electrical circuit diagram related to engine oil level switch
PC400LC-7L
20-453
B@BCNS
12
B@BCNS
ENGINE WATER OVERHEAT
Contents Of Trouble
The signal circuit of the engine water temperature sensor detected temperature above 105C. (Mechanical system)
Failure code B@BCNS.
None in particular.
Phenomenon occurring on
machine
If the engine water temperature monitor on the monitor panel lights up in red while the engine is running, this failure
code is recorded.
Input from the engine water high temperature sensor (water temperature and voltage) can be checked in the monitoring
function.
(Code No.: 04102 Engine water temperature (High),
Code No.: Engine water temperature sensor voltage Hi)
Relative information
Steps
Specifications
No.
Readings
1.
Check the engine for overheating. If it has been overheated, find out the cause and check the engine
for damage, then repair.
2.
Carry out troubleshooting for Display of engine water temperature gauge on monitor panel is
abnormal in E mode.
3.
Engine controller
Hold ignition switch in the ON position or start engine during the troubleshooting.
A.
20-454
Resistance
3.28k
3.28k
PC400LC-7L
B@BCNS
12
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
PC400LC-7L
20-455
B@BCZK
12
B@BCZK
ENGINE WATER LEVEL LOW
The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the engine is running. (Mechanical system)
Failure code B@BCZK.
None in particular.
Phenomenon occurring on
machine
If the radiator water level monitor on the monitor panel lights up red while the engine is stopped (the ignition switch is
at the ON position), this failure code is recorded.
Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.
(Code No.: 04500 Monitor input 1)
Contents Of Trouble
Relative information
Steps
1.
2.
3.
No.
Readings
A33
--Below 1
Above 1M
Below 1
Below 1
Below 1V
20 - 30V
Wiring harness
4.
Specifications
Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the
cause.
Resistance
Monitor panel
Hold ignition switch in the ON position or start engine during the troubleshooting.
A.
20-456
Voltage
PC400LC-7L
B@BCZK
PC400LC-7L
20-457
B@HANS
12
B@HANS
HYDRAULIC OIL OVERHEAT
Contents Of Trouble
The signal of the hydraulic oil temperature sensor rises above 102C, while the engine is running. (Mechanical system)
Failure code B@HANS.
None in particular.
Phenomenon occurring on
machine
If the hydraulic oil temperature monitor on the monitor panel lights up red while the engine is running, this failure code
is recorded.
Input from the hydraulic oil temperature sensor can be checked in the monitoring function.
(Code No.: 04401 Hydraulic oil temperature)
Relative information
Steps
1.
2.
3.
A61
Resistance
No.
Readings
10 - 100C
--90 - 3.5k
Above 1M
Above 1M
90 - 3.5k
Above 1M
Wiring harness
4.
Specifications
Check the hydraulic oil for overheating. If it has been overheated, find out the cause and check the
hydraulic equipment for damage, then repair.
Resistance
Monitor panel
Hold ignition switch in the ON position or start engine during the troubleshooting.
A.
20-458
Resistance
PC400LC-7L
B@HANS
PC400LC-7L
20-459
B@HANS
12
MEMORANDUM
20-460
PC400LC-7L
PC400LC-7L
20-501 1
TROUBLESHOOTING
TABLE OF CONTENTS
20-502 1
PC400LC-7L
TROUBLESHOOTING
12
This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a
device which supplies power while the starting switch is at the OFF position).
When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is
supplied normally.
Fuse No.
Fuse capacity
Destination of power
Pump controller (Controller power supply)
10 A
20 A
Constant power
supply
(Fusible link: A35)
PC400LC-7L
10 A
10 A
10 A
Horn
10 A
(Spare)
10 A
Rotary lamp
10 A
10 A
10
10 A
(Spare)
11
20 A
12
20 A
13
20 A
14
10 A
15
10 A
16
10 A
17
10 A
18
10 A
Starting switch
19
10 A
Room lamp
20
10 A
(Spare)
Monitor panel
Starting motor cutout relay (For personal code)
Light relay (For right front working lamp & boom working lamp)
Headlamp & additional headlamp
Service power supply 1 (M32 connector)
Travel alarm
Service power supply 2 (DC/DC converter)
20-503 1
TROUBLESHOOTING
12
2.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3.
Always connect any disconnected connectors before going on to the next step.
If power is turned ON with the connectors still disconnected, unnecessary displays will be generated.
4.
When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
If there is any charge, there is probably defective contact in that circuit.
5.
6.
7.
20-504 1
PC400LC-7L
TROUBLESHOOTING
12
POINTS
ITSELF
There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1.
2.
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the connector is returned
to its original position when carrying out troubleshooting on the failure, and the service code is no longer displayed, or if
the monitor display returns to normal.
3.
After completing troubleshooting, always erase the user code from memory.
PC400LC-7L
20-505 1
TROUBLESHOOTING
12
Contents Of Trouble
Steps
1.
What you
testing
are
4.
No.
Readings
Resistance
or
Voltage
readings
Your
information
readings
Your
information
Diode test
With ignition switch in the OFF position. (The importance of these tests are to isolate each component for testing separately)
When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm electrical
flow. Electrical flow should be one way only.
A.Diode test
3.
Specifications
Sensor or actuator
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.
2.
Failure.
Failure code displayed.
Additional information.
Resistance
Continuity one
way only?
Yes or No
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.Open or high
resistance
Resistance
or
Voltage
readings
Your
information
readings
Your
information
Resistance
or
Voltage
readings
Your
information
readings
Your
information
With ignition switch in the OFF position. (no voltage should be in the system you are testing unless called for indicated with a symbol )
Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
Zero meter leads for proper readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
A.What you are
testing
20-506 1
Resistance
or
Voltage
readings
Your
information
PC400LC-7L
TROUBLESHOOTING
12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
PC400LC-7L
20-507 1
TROUBLESHOOTING
E-1
12
E-1
THE ENGINE DOES NOT CRANK
Relative information
The engine starting circuit has the start lock mechanism of the safety lock lever type
Failure information
Steps
1.
A.
Battery test
Insufficient capacity
Voltage
---
Battery voltage
Min. 24V
Min. 1.26
3.
Fuse No. 3 or 17
4.
Ignition switch
If circuit breaker is turned OFF or the fuse is broken, the circuit probably has a ground fault (See cause 9).
Resistance
Min. 1M
Max. 1
Resistance
Min. 1M
Max. 1
A.
7.
Readings
6.
No.
2.
5.
Specifications
Battery
Resistance
100 - 500
Min. 1M
Max. 1
100 - 500
Min. 1M
10
Max. 1
11
Starting motor
A.
B - power supply
20 - 30V
12
S - start
20 - 30V
13
R - charge
Max. 1V
14
Voltage
If the above voltage is normal and the starting motor does not crank, starting motor has a defect in it
or engine is defective.
8.
Alternator
Prepare with ignition switch OFF (with only wiring harness R disconnected).
Alternator test
Internal short circuit
20-508 1
Voltage
Max. 1V
15
PC400LC-7L
TROUBLESHOOTING
Steps
9.
E-1
Specifications
No.
Readings
Disconnect A35, H15, R1, R13, S14 connectors from and install T-adapter.
A.
Wiring harness
Disconnection in
harness or defective
contact in connector
Resistance
Resistance
B.
C.
Wiring harness
Short to chassis
ground or within
harness
Contact with ground
circuit
Wiring harness
Contact with 24V
circuit
PC400LC-7L
Voltage
Max. 1
16
Max. 1
17
Max. 1
18
Max. 1
19
Max. 1
20
Max. 1
21
Max. 1
22
Max. 1
23
Min. 1M
24
Between H15 (4), J01 and R11 (5) and other related
circuits and chassis ground
Min. 1M
25
Min. 1M
26
Min. 1M
27
Min. 1M
28
Min. 1M
29
Between R13 (2), J05, P02 (14 and other related circuits
and chassis ground
Min. 1M
30
Max. 1V
31
20-509 1
TROUBLESHOOTING
E-1
20-510 1
PC400LC-7L
TROUBLESHOOTING
E-2
12
E-2
PREHEATER DOES NOT OPERATE
PREHEATING MONITOR DOES NOT LIGHT
Failure information
Relative information
The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about 30 seconds, it start
flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
Input of the preheating signal (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)
Steps
1.
Ignition switch
defective
2.
Wiring harness
3.
1. When the starting switch is turned to the HEAT position, the preheating
monitor does not light up.
system
Specifications
No.
Readings
If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting
Resistance
Below 1
Below 1V
20 - 30V
Monitor panel
PC400LC-7L
Voltage
20-511 1
TROUBLESHOOTING
12
HEATER
E-2
Relative information
Failure information
Steps
1.
A.
2.
Readings
Resistance
Above 1M
Below 1
Continuity and
Resistance
Ignition switch
OFF
HEAT
Heater relay
---
Continued
Below 1
Continued
4.
No.
Heater relay
3.
Specifications
Ignition switch
Continuity
Wiring harness
20-512 1
Resistance
Below 1
Below 1
Below 1
Below 1
PC400LC-7L
TROUBLESHOOTING
E-2
12
Electrical circuit diagram for engine preheating, starting, charging
PC400LC-7L
20-513 1
TROUBLESHOOTING
E-3
12
E-3
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK
Failure information
Relative information
The auto engine warm-up device is activated, when the engine cooling water temperature is below 30C, and raise the engine
rotation up to 1,200 rpm.
The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more than 3 seconds, when
the engine starting switch is in the ON position or after the engine is started.
If the engine water temperature is below 10C, the turbocharger protection function operates to keep the engine speed below
1,000 rpm for up to 5 seconds after the engine is started.
Steps
1.
Specifications
No.
Readings
A.
Monitor code
04107
Compare the
monitor
indication with
the actual engine
cooling water
temperate
If the display on the monitor panel is abnormal, carry out troubleshooting in Engine water thermometer does not display normally.
2.
Engine controller
A.
20-514 1
If step1 is not detected, the engine controller may be defective. (Since trouble is in the engine controller, troubleshooting
cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-4
12
E-4
AUTO-DECELERATOR DOES NOT OPERATE
Failure information
Relative information
Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above this level.
Check the display on the monitor panel while the engine is running.
If the display on the monitor panel is abnormal, carry out troubleshooting in *** is not displayed normally in monitoring
function.
---
Cause
Item
Normal display
01900
Pressure switch 1
Boom RAISE
Lever operation: ON
Lever NEUTRAL: OFF
01900
Pressure switch 1
Boom LOWER
Lever operation: ON
Lever NEUTRAL: OFF
01900
Pressure switch 1
Arm RETRACT
Lever operation: ON
Lever NEUTRAL: OFF
01900
Pressure switch 1
Arm EXTEND
Lever operation: ON
Lever NEUTRAL: OFF
01901
Pressure switch 2
Bucket CURL
Lever operation: ON
Lever NEUTRAL: OFF
01901
Pressure switch 2
Bucket DUMPING
Lever operation: ON
Lever NEUTRAL: OFF
01900
Pressure switch 1
Swing
Lever operation: ON
Lever NEUTRAL: OFF
01900
Pressure switch 1
Travel
Lever operation: ON
Lever NEUTRAL: OFF
01901
Pressure switch 2
Service
Lever operation: ON
Lever NEUTRAL: OFF
10
As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1
through 9, the controller is judged as defective.
11
As this is an internal failure, testing cannot be conducted. (If there is none of the causes listed in Item 1
through 9, the controller is judged as defective.
PC400LC-7L
20-515 1
TROUBLESHOOTING
E-5
12
E-5
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE
Relative information
---
Failure information
Steps
1.
1.
2.
Readings
Resistance
Below 1
Above 1M
20 - 60
Resistance
Above 1M
Above 1M
( Continuity)
4.
No.
3.
Specifications
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.
Resistance
Wiring harness
B.
Resistance
Resistance
20-516 1
Below 1
Below 1
Below 1
Above 1M
Above 1M
10
Above 1M
11
PC400LC-7L
TROUBLESHOOTING
E-5
12
Electrical circuit diagram for PPC lock solenoid
PC400LC-7L
20-517 1
TROUBLESHOOTING
E-6
12
E-6
ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE
Failure information
Relative information
If the one-touch power max. switch is pressed while the engine is running, the one-touch power max. monitor is displayed
on the monitor panel.
Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in the monitoring
function. (Code No. 02200: Switch input 1)
Steps
1.
1.
2.
No.
Readings
Resistance
At
M23, One touch pwr. max. sw. - released
between (1) and
One touch pwr. max. sw. - Pressed
(2)
Min. 1M
Max. 1
Max. 1
Wiring harness
B.
3.
Specifications
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 2B.
Resistance
Min. 1M
Resistance
Min. 1M
Max. 1V
20 - 30V
Pump controller
20-518 1
Voltage
At
C01, One touch pwr. max. sw. - released
Between
(11)
One touch pwr. max. sw. - Pressed
and ground
PC400LC-7L
TROUBLESHOOTING
E-6
12
Electrical circuit diagram related to one-touch power max. switch
PC400LC-7L
20-519 1
TROUBLESHOOTING
E-7
12
E-7
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE
Machine push-up function does not operate
normally.
Relative
information
When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
Failure
information
Steps
1.
Specifications
No.
Readings
2.
Machine
push-up
switch test
Internal disconnection
Resistance
At
M38, Low pressure position
between (1) and
High pressure position
(2)
Below 1
Above 1M
Below 1V
Below 1V
Wiring harness
20-520 1
Voltage
PC400LC-7L
TROUBLESHOOTING
12
MACHINE
E-7
Relative information
When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
Failure information
Steps
1.
1.
Specifications
No.
Readings
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.
2.
Below 1
Above 1M
Machine push-up
solenoid
Internal
disconnection, short circuit or
ground fault
20 - 60
Resistance
Above 1M
Above 1M
( Continuity)
4.
Resistance
At
M38, Low pressure position
between (1) and
High pressure position
(2)
3.
Machine
push-up
switch test
Internal disconnection
Resistance
Wiring harness
B.
PC400LC-7L
Resistance
Resistance
Below 1
Below 1
Below 1
Above 1M
Above 1M
10
Above 1M
11
Between FB1 (2) outlet and M38 (1) and related circuits
and grounding
20-521 1
TROUBLESHOOTING
E-7
12
Electrical circuit diagram related to machine push-up solenoid
20-522 1
PC400LC-7L
TROUBLESHOOTING
E-7
12
MEMORANDUM
PC400LC-7L
20-523 1
TROUBLESHOOTING
E-8
12-
E-8
ATTACHMENT CIRCUIT DOES NOT CHANGE
WHEN ATTACHMENT IS INSTALLED
(1)When working mode A or E is selected, attachment circuit is not switched to crusher
Attachment circuit does not change. circuit (reciprocation circuit).
(2)When working mode B is selected, attachment circuit is not switched to breaker circuit
(one-way circuit).
Relative information
If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or disconnection), an error code is
displayed. A fault on the secondary side (contact side) cannot be detected, however.
Failure information
Steps
1.
A.
2.
No.
Readings
Attachment
return
selection solenoid test
Internal disconnection
20 - 60
Above 1M
Below 1
Above 1M
3.
Specifications
Attachment
return
selection relay
Internal
disconnection, short
circuit or ground fault
Resistance
Wiring harness
B.
Resistance
Voltage
20-524 1
Below 1
Below 1
Below 1
Below 1V
PC400LC-7L
TROUBLESHOOTING
E-8
12
Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
PC400LC-7L
20-525 1
TROUBLESHOOTING
E-9
12
E-9
NO DISPLAY IN MONITOR PANEL AT ALL
Relative information
---
Failure information
Steps
1.
2.
Wiring harness
B.
3.
Specifications
No.
Readings
If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 2B.
Resistance
Resistance
Below 1
Below 1
Above 1M
Starting Switch
At P01, between (1), (2) and ground
ON
20 - 30V
Starting
OFF
Below 1
Monitor panel
20-526 1
switch
PC400LC-7L
TROUBLESHOOTING
E-9
12
Electrical Circuit Diagram for Power Source in Monitor Panel
PC400LC-7L
20-527 1
TROUBLESHOOTING
E-10
12
E-10
PART OF DISPLAY ON MONITOR PANEL IS MISSING
Failure information
Part of display on monitor panel is missing Part of the display in the monitor panel is missing during starting switch in ON.
Relative information
---
Cause
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen becomes totally white) by the
following switching operation, then the monitor panel is normal.
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting
cannot be carried out.)
E-11
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL
Failure information
Relative information
---
The monitor panels displays contents that have nothing to do with the model on which it is installed.
Cause
Monitoring code
Item
Normal display
00200
PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
2.
20-528 1
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in the monitor panel, troubleshooting cannot
be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-12
12
E-12
FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING
The fuel level monitor red lamp lights up while the engine was running.
Relative information
If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
(5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel level sensor)
Failure information
Steps
1.
2.
Specifications
No.
Readings
Fuel level
A.
3.
Resistance
At A60, between
(1) and
grounding
Approximately
12
85 - 110
Below 1
Approximately
12
85 - 110
Wiring harness
4.
Resistance
Monitor panel
Resistance
At A60, between
(2) and
grounding
PC400LC-7L
20-529 1
TROUBLESHOOTING
E-13
12
E-13
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY
Failure
information
Relative
information
2.
Specifications
No.
Readings
2.
The signal of the engine water high temperature sensor for the water temperature gauge is received from the engine controller
through the communication line.
If the engine water high temperature sensor system becomes defective, error code [E934] may be displayed.
Input from the engine water high temperature sensor (voltage and temperature) can be checked in the monitoring function.
(Code No. 04106: Engine water sensor voltage Hi,
Code No. 04102: Engine water temperature (High temperature))
Steps
1.
1.
Resistance
3.5k - 90k
Above 1M
Above 1M
Wiring harness
B.
C.
3.
Resistance
Resistance
Voltage
Below 1
Below 1
Below 1
Above 1M
Below 1V
Engine controller
A.
4.
Monitor panel
20-530 1
Resistance
3.5k - 90k
3.5k - 90k
10
Above 1M
11
Above 1M
12
Above 1M
13
If causes 1 - 3 are not detected, the monitor panel may be defective. (Since trouble is in the monitor panel,
troubleshooting cannot be carried out.)
PC400LC-7L
TROUBLESHOOTING
E-13
12
Electrical circuit diagram related to engine water high temperature sensor
PC400LC-7L
20-531 1
TROUBLESHOOTING
E-14
12
E-14
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY
Failure information
Relative information
1.
Hydraulic oil temperature rises normally, but the display does not rise from the white range (C).
2.
Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
(Code No.: 04401 Hydraulic oil temperature)
Steps
1.
Specifications
No.
Readings
2.
Hydraulic oil
temperature sensor test
Resistance
- Internal
disconnection, short
circuit, ground fault
90 - 3.5k
Above 1M
Below 1
Below 1
Above 1M
Below 1V
90 - 3.5k
90 - 3.5k
10 - 100C
At A61, between
grounding
(2)
and
Wiring harness
B.
C.
3.
Resistance
Voltage
Monitor panel
20-532 1
Resistance
10 - 100C
PC400LC-7L
TROUBLESHOOTING
E-14
12
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC400LC-7L
20-533 1
TROUBLESHOOTING
E-15
12
E-15
FUEL GAUGE DOES NOT DISPLAY CORRECTLY
Failure information
Relative information
1.
Though fuel was refilled, the display does not exceed the red range (E).
2.
Though the remaining fuel level is low, the display does not drop below the green range (F).
Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel sensor voltage)
Steps
1.
Specifications
No.
Readings
2.
At A60, between
grounding
(1)
and
Approximately
12
85 - 110
Below 1
Above 1M
Below 1V
Approximately
12
85 - 110
Wiring harness
B.
C.
3.
Voltage
Monitor panel
Resistance
20-534 1
PC400LC-7L
TROUBLESHOOTING
E-15
12
Electrical Circuit Diagram for Fuel Level Sensor
PC400LC-7L
20-535 1
TROUBLESHOOTING
E-16
12
E-16
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY
Failure information
Relative information
Though the swing lock switch was turned ON, the swing lock monitor
does not light up.
2.
Though the swing lock switch was turned OFF, the swing lock monitor
lights up.
Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Steps
1.
1.
Specifications
No.
Readings
2.
OFF
Above 1M
Below 1
Below 1
Below 1
Above 1M
Above 1M
Below 1V
Below 1V
ON
Wiring harness
B.
C.
3.
Resistance
Resistance
Voltage
Monitor panel
20-536 1
Voltage
OFF
ON
20 30
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-16
12
Electrical circuit diagram related to swing holding brake solenoid
PC400LC-7L
20-537 1
TROUBLESHOOTING
E-17
12
E-17
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED
Failure information
Relative information
---
Failure information
(2) When LCD monitor adjustment switch is operated, mode selection screen is
not displayed.
Relative information
---
Cause
(1) When mode selector switch is operated, working mode monitor is not
displayed.
Cause
Failure information
(3) When selector switch is operated, flow rate adjustment screen or flow rate
selection screen is not displayed.
Relative information
---
Failure information
(4) When maintenance switch is operated, item selection screen is not displayed.
Relative information
---
Cause
Cause
Failure information
Relative information
When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.
Cause
Failure information
(6) When travel speed selector switch is operated, travel speed monitor is not
displayed.
Relative information
When the travel speed does not change either, conduct the troubleshooting for H-22.
Failure information
Relative information
When the wiper does not operate either, conduct the troubleshooting for E-18.
20-538 1
Cause
Cause
Monitor panel defective
PC400LC-7L
TROUBLESHOOTING
E-17
12
MEMORANDUM
PC400LC-7L
20-539 1
TROUBLESHOOTING
E-18
12
E-18
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK
WINDSHIELD WIPER DOES NOT WORK
Failure information
Relative information
Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Steps
1.
Specifications
No.
Readings
2.
Above 1M
Below 1
Continued
Below 1
Below 1
Above 1M
20 - 30V
Below 1V
Windshield
wiper Continuity
motor test - Internal and resistance value
disconnection
Wiring harness
B.
4.
Turn ignition switch OFF or keep the engine running during troubleshooting.
A.
3.
Resistance
5.
Monitor panel
(Window rear limit
switch system) test
Monitor panel
(Windshield
wiper
motor system) test
20-540 1
OFF
Voltage
ON
Below 3V
At P01, between (9) and ground
Below
3V 20 At P01, between (10) and
30V (Constant
ground
cycle)
9
10
PC400LC-7L
TROUBLESHOOTING
E-18
12
Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
PC400LC-7L
20-541 1
TROUBLESHOOTING
12
WINDSHIELD
E-18
Relative information
---
Failure information
Steps
1.
Fuse No. 4
2.
Turn ignition switch OFF or keep the engine running during troubleshooting.
A.
3.
No.
Readings
Windshield
wiper
At A50, between (1) and (2)
motor test - Internal Resistance
At A50, between (1) and ground
disconnection
5 - 20
Above 1M
Below 1
Below 1
Above 1M
Above 1M
Above 1M
Above 1M
Wiring harness
Resistance
From FB1 (4) to D02 (4) and to other relative circuits and
Resistance grounding
From A50 (2) to J04 and P01 (3) and grounding
From A50 (2) to D02 (8) and grounding
4.
Specifications
If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 3B.)
Monitor panel
20-542 1
Voltage
OFF
ON
20 - 30V
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-18
12
Electrical Circuit Diagram for Window Washer Motor
PC400LC-7L
20-543 1
TROUBLESHOOTING
E-19
12
E-19
ALARM BUZZER CANNOT BE CANCELLED
Relative information
Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Failure information
Steps
1.
Specifications
No.
Readings
2.
Release
Above 1M
Depress
Below 1
Below 1
Below 1
Below 1V
20 - 30V
Below 1V
Wiring harness
B.
3.
Resistance
Voltage
Monitor panel
20-544 1
Voltage
Release
Depress
PC400LC-7L
TROUBLESHOOTING
E-19
12
Electrical circuit diagram related to alarm buzzer stop switch
PC400LC-7L
20-545 1
TROUBLESHOOTING
E-20
12
E-20
BOOM RAISE IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Boom RAISE
Below 1
Below 1
Wiring harness
B.
C.
3.
Resistance
Below 1
Above 1M
Below 1V
20 - 30V
Below 1V
Voltage
Pump controller
20-546 1
Voltage
NEUTRAL
Boom RAISE
PC400LC-7L
TROUBLESHOOTING
E-20
12
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC400LC-7L
20-547 1
TROUBLESHOOTING
E-21
12
E-21
BOOM LOWER IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Boom LOWER
Below 1
Below 1
Wiring harness
B.
C.
3.
Resistance
Below 1
Above 1M
Below 1V
20 - 30V
Below 1V
Voltage
Pump controller
20-548 1
Voltage
NEUTRAL
Boom LOWER
PC400LC-7L
TROUBLESHOOTING
E-21
12
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
PC400LC-7L
20-549 1
TROUBLESHOOTING
E-22
12
E-22
ARM IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION
Failure information
Relative information
---
Cause
1.
The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for error code [E247].
2.
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot
be carried out since the defect is in the pump controller).
20-550 1
PC400LC-7L
TROUBLESHOOTING
E-23
12
E-23
ARM DUMPING IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Arm DUMPING
Below 1
Below 1
Wiring harness
B.
C.
3.
Resistance
Below 1
Above 1M
Below 1V
20 - 30V
Below 1V
Voltage
Pump controller
PC400LC-7L
Voltage
NEUTRAL
Arm DUMPING
20-551 1
TROUBLESHOOTING
E-23
20-552 1
PC400LC-7L
TROUBLESHOOTING
E-24
12
E-24
BUCKET CURL IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION
Failure information
Bucket CURL is not displayed normally in monitoring Bucket CURL is not displayed normally in monitoring function (special
function.
function) of monitor panel.
Relative information
---
Cause
1.
2.
PC400LC-7L
If cause 1 is not the cause of the trouble, the pump controller may be defective (Troubleshooting cannot be
carried out since the defect is in the pump controller).
20-553 1
TROUBLESHOOTING
E-25
12
E-25
BUCKET DUMPING IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Bucket DUMPING
Below 1
Below 1
Bucket
DUMPING
At S05, between (1) and
PPC hydraulic switch
Resistance
(2)
test - Internal
disconnection
Wiring harness
B.
C.
3.
Resistance
Below 1
Above 1M
Below 1V
20 - 30V
Below 1V
Voltage
Pump controller
20-554 1
Voltage
NEUTRAL
Bucket DUMPING
PC400LC-7L
TROUBLESHOOTING
E-25
PC400LC-7L
20-555 1
TROUBLESHOOTING
E-26
12
E-26
SWING IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION
Swing is not displayed normally in monitoring function.
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
Swing
left
PPC
At S07, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection
NEUTRAL
Min. 1M
Max. 1
NEUTRAL
Min. 1M
Max. 1
3.
Swing
right
PPC
At S03, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection
Wiring harness
B.
C.
4.
Resistance
Resistance
Voltage
Max. 1
Max. 1
Max. 1
Max. 1
Min. 1M
Min. 1M
10
Max. 1V
11
Max. 1V
12
20 - 30V
13
Max. 1V
14
Pump controller
20-556 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E-26
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC400LC-7L
20-557 1
TROUBLESHOOTING
E-27
12
E-27
TRAVEL IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
TRAVEL is not correctly displayed in monitor function
TRAVEL is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Forward or reverse
Below 1
Below 1
Below 1
Above 1M
Above 1M
Below 1V
Below 1V
Wiring harness
B.
C.
3.
Resistance
Resistance
Voltage
Pump controller
20-558 1
Voltage
NEUTRAL
Forward or backward
20 - 30V
Below 1V
10
PC400LC-7L
TROUBLESHOOTING
E-27
12
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
PC400LC-7L
20-559 1
TROUBLESHOOTING
E-28
12
E-28
TRAVEL DIFFERENTIAL PRESSURE IS NOT CORRECTLY DISPLAYED IN
MONITOR FUNCTION
Relative information
When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential
mechanism is turned ON.
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Below 1
Below 1
Below 1
Above 1M
Below 1V
20 - 30V
Below 1V
Wiring harness
B.
C.
3.
Resistance
Voltage
Pump controller
20-560 1
Voltage
PC400LC-7L
TROUBLESHOOTING
E-28
12
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
PC400LC-7L
20-561 1
TROUBLESHOOTING
E-29
12
E-29
SERVICE IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
Relative information
---
Failure information
Steps
1.
Specifications
No.
Readings
2.
NEUTRAL
Above 1M
Operated to front
Below 1
NEUTRAL
Above 1M
Operated to rear
Below 1
3.
Wiring harness
B.
C.
4.
Below 1
Below 1
Below 1
Above 1M
Resistance
Above 1M
Below 1V
10
Voltage
Below 1V
11
Pump controller
20-562 1
Voltage
NEUTRAL
At C02, between (35) and
Operated to front or rear ground
20 - 30V
Below 1V
PC400LC-7L
TROUBLESHOOTING
E-29
12
Electrical Circuit Diagram for Service PPC hydraulic Switch
PC400LC-7L
20-563 1
TROUBLESHOOTING
E-30
12
E-30
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING
Failure information
Relative information
1.
The travel alarm does not sound while the machine is traveling.
2.
---
Steps
1.
Fuse No. 15
2.
Travel signal
3.
No.
Readings
Monitoring code
01900
Item
Normal display
Travel
Wiring harness
B.
4.
Specifications
When fuse No. 15 is blown, there is a big possibility that ground fault occurred in the circuit. (See Step 3B.)
Below 1
Below 1
Above 1M
Above 1M
Resistance
Travel alarm
20-564 1
This is an internal failure, troubleshooting cannot be conducted. (If none of the causes listed in item 1 through 4 above is
found, the travel alarm is judged as defective.)
PC400LC-7L
TROUBLESHOOTING
E-30
12
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
PC400LC-7L
20-565 1
TROUBLESHOOTING
E-32
12
E-32
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM
The control panel of the air conditioner constantly monitors the sensors and other devices in the system.
When it detects any abnormality, Self-diagnosis notice is displayed by operating switches specially.
If you feel any abnormality in the air conditioner system, check the Self-diagnosis notice first according to the
procedure for Troubleshooting by self-diagnosis notice, and then;
If the Self-diagnosis notice is displayed, continue the Troubleshooting by self-diagnosis notice.
If the Self-diagnosis notice is not displayed, carry out the Troubleshooting by failure phenomenon.
Failure mode
E--
No failures
E11
E12
E15
E16
E18
E43
E44
E45
Check the Self-diagnosis notice on the control panel according to the following procedure.
1.
2.
Press OFF switch (1) and check that anything is not displayed on
display monitor (2).
3.
4.
20-566 1
PC400LC-7L
TROUBLESHOOTING
12
E-32-E11
Self-diagnosis notice
Trouble
E11
Contents of trouble
Related information
No.
Readings
Recirculation air
sensor test - Internal
disconnection
300 430k
Max. 1
Max. 1
Wiring harness
3.
Specifications
2.
Steps
1.
E-32
Resistance
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
Trouble
E12
Contents of trouble
Related information
---
Steps
1.
No.
Readings
Recirculation air
sensor test - Internal
disconnection
300 430k
Max. 1
Max. 1
Wiring harness
3.
Specifications
2.
PC400LC-7L
Resistance
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
20-567 1
TROUBLESHOOTING
12
E-32-E15
Self-diagnosis notice
Trouble
E15
Contents of trouble
Related information
Ignores the warm-up control and fixes the engine water temperature at 60C for control.
When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> +
<Starting air conditioner>
---
Steps
1.
E-32
Specifications
No.
Readings
2.
Water temperature
sensor test - Internal
disconnection
95 455k
Max. 1
Max. 1
Wiring harness
3.
Resistance
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
Trouble
E16
Contents of trouble
Related information
Ignores the warm-up control and fixes the engine water temperature at 60C for control.
When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF and ON> +
<Starting air conditioner>
---
Steps
1.
No.
Readings
Water temperature
sensor test - Internal
disconnection
95 455k
Max. 1
Max. 1
Wiring harness
3.
Specifications
2.
20-568 1
Resistance
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
PC400LC-7L
TROUBLESHOOTING
12
E-32-E18
E-32
Self-diagnosis notice
Trouble
E18
Contents of trouble
Related information
---
Steps
1.
Daylight sensor
2.
Wiring harness
3.
Specifications
No.
Readings
Resistance
Max. 1
Max. 1
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
Trouble
E43
Contents of trouble
Related information
Steps
Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output shaft and break the motor coils.
Circuit Diagnostic Procedures For Code [---]
1.
2.
Wiring harness
3.
PC400LC-7L
Specifications
No.
Readings
Max. 1
Max. 1
Max. 1
Max. 1
Max. 1
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
20-569 1
TROUBLESHOOTING
12
E-32-E44
E-32
Self-diagnosis notice
Trouble
E44
Contents of trouble
Related information
Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the
motor output shaft and break the motor coils.
Steps
1.
2.
Wiring harness
3.
Specifications
No.
Readings
Max. 1
Max. 1
Max. 1
Max. 1
Max. 1
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
Trouble
E45
Contents of trouble
Related information
Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output
Steps
1.
2.
3.
Wiring harness
4.
Specifications
No.
Readings
20-570 1
If the fuse (in unit) is broken, the circuit probably has a ground fault, etc. Check the related circuits.
Max. 1
Max. 1
Max. 1
If neither of Steps 1 and 2 is the cause of the trouble, the air conditioner system may be defective. Refer to CHASSIS
COMPENT, Shop Manual, Air conditioner.
PC400LC-7L
TROUBLESHOOTING
E-32
12
Electrical Circuit Diagram for Air Conditioner
PC400LC-7L
20-571 1
TROUBLESHOOTING
12
E-32
E-32
Trouble
Related information
---
Steps
Fuse No. 11
2.
Wiring harness
B.
Specifications
No.
Readings
If the fuse is broken, the circuit probably has a ground fault, etc. Refer to cause 3.
Resistance
Max. 1
Max. 1
Max. 1
Max. 1
Min. 1
Min. 1
Wiring harness
Between fuse (11) and M33 (3) and chassis ground
Contact with ground Resistance
Between M27 (14) and M30 (6) and chassis ground
circuit
4.
1.
3.
1.
Voltage
At M33, between (2) and (3)
20 - 30V
7
Air conditioner unit
test
If the above voltage is normal and the air conditioner does not operate, the air conditioner is defective.
Control panel
Voltage
20 - 30V
8
9
If the above voltage is normal and the air conditioner does not operate, the control panel is defective.
20-572 1
PC400LC-7L
TROUBLESHOOTING
E-32
12
Trouble
2.
Related information
Steps
1.
2.
Blower relay
3.
Readings
140 - 340
Voltage
20 - 30V
Power transistor
5.
No.
Blower relay
4.
Specifications
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
Fan switch
Operate in rang of Low, If air flow can be changed with fan switch, power
Medium and High
transistor is normal.
Blower motor
Fan switch
Voltage
ON
20 - 30V
If the above voltage is normal and the blower motor does not rotate, the blower motor is defective.
6.
Wiring harness
Disconnect R30, R31, Mb, Ptr, M27, M29 and M30 and install T-adapters.
7.
PC400LC-7L
Max. 1
Max. 1
Max. 1
Max. 1
Max. 1
9
10
Max. 1
Max. 1
11
Max. 1
12
If none of Steps 1 - 6 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT,
Shop Manual, Air conditioner.
20-573 1
TROUBLESHOOTING
E-32
12
Trouble
3.
Related information
Steps
1.
2.
Compressor relay
3.
Specifications
No.
140 - 340
Compressor relay
Turn ignition switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position).
A.
Voltage
4.
5.
High/Low
switch test
pressure
20 - 30V
2
3
Max. 1
6.
Compressor clutch
7.
Compressor
8.
Wiring harness
A.
9.
Readings
If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.
20-574 1
Resistance
Max. 1
Max. 1
Between fuse 11 outlet, R31 (2), fuse in unit, R31 (1) and
M30 (6)
Max. 1
9
10
Max. 1
Max. 1
11
Max. 1
12
Max. 1
13
If none of Steps 1 - 8 is the trouble, the air conditioner system may be defective. Refer to CHASSIS COMPONENT,
Shop Manual, Air conditioner.
PC400LC-7L
TROUBLESHOOTING
E-32
12
Electrical Circuit Diagram for Air Conditioner
PC400LC-7L
20-575 1
TROUBLESHOOTING
E-32
12
MEMORANDUM
20-576 1
PC400LC-7L
PC400LC-7L
20-601 1
TABLE OF CONTENTS
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
MACHINE DOES NOT SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
EXCESSIVE OVERRUN WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
H-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
THERE IS BIG SHOCK WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
H-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING . . . . . . . . . . . . . . . . . . . . 20-624
H-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
SWING NATURAL DRIFT IS TOO BIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-625
H-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
H-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . 20-626
20-602 1
PC400LC-7L
PC400LC-7L
20-603 1
20-604 1
PC400LC-7L
TROUBLESHOOTING
12
Relative information
Cause
1
2
3
The standard values in normalcy by which to judge good or no good about presumed causes.
reference purpose only. It does
4
5
PC400LC-7L
20-605 1
TROUBLESHOOTING
H-1
12
H-1
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS
ARE SLOW
Failure information
All the work equipment lack power, or their travel and swing speeds are slow.
Relative information
Cause
Malfunctioning of
unload valve
Control lever
Unload pressure
Malfunctioning of self
pressure decompression
valve
Improper adjustment or
malfunctioning of PC
valve
Measurement condition
Swing lock: ON
Arm: Digging relief
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of PC valve or its internal
failure is suspected. In that case, check the valve itself.
Travel speed
Lo
NEUTRAL
Hi
OPERATED
0 MPa {0 kgf/cm2}
Improper adjustment or
malfunctioning of LS
valve
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of LS valve or its internal
failure is suspected. In that case, check the valve itself.
7
Malfunctioning of servo Malfunctioning of servo piston is suspected. Check the piston itself.
piston
20-606 1
If none of the above listed causes is detected, the piston pump is suspected of deteriorated performance,
malfunctioning or internal failure.
PC400LC-7L
TROUBLESHOOTING
H-2
12
H-2
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS
Failure information
Relative information
Relative Information
Cause
Improper adjustment or
malfunctioning of main relief
valve
Control lever
Arm, DIGGING
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the main relief valve
or its internal failure is suspected. In that case, check the valve itself.
Improper adjustment or
malfunctioning of PC valve
Measurement condition
Swing lock: ON
Arm: Digging relief
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the PC valve or its
internal failure is suspected. In that case, check the valve itself.
Improper adjustment or
malfunctioning of LS valve
1
Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its
internal failure is suspected. In that case, check the valve itself.
4
The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.
Malfunction of servo
piston
PC400LC-7L
20-607 1
TROUBLESHOOTING
H-3
12
H-3
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE
Failure information
No work equipment nor travel and swing functions can be set in motion.
Relative information
Cause
Locked
Released
Malfunctioning of self
pressure decompression valve
Control lever
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in the following manner.
Remove the main oil pressure measurement plug and crank the engine. If oil flows out, it is in normal
condition.
Damper defective
It is presumed that the pump shaft does not rotate due to some internal failure of the damper. Check the damper
itself.
H-4
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP
An abnormal noise is heard from around the hydraulic pump.
Relative information
---
Failure information
Cause
Air may have get mixed with the oil. Make a visual check.
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby causing negative pressure inside
the tank. Make a visual check.
It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
negative pressure in the suction circuit. Make a visual check.
The piston pump is suspected of an internal failure. Check the pump itself.
20-608 1
PC400LC-7L
TROUBLESHOOTING
H-5
12
H-5
AUTO-DECELERATOR DOES NOT WORK
Failure information
Relative information
This troubleshooting mode is applied when the auto-decelerator does not work, while operating the travel control
lever. (A shuttle valve is provided between PPC valve and the hydraulic switch only in the travel circuit -actually
located inside PPC valve)
Set the working mode at A mode for the troubleshooting.
Cause
NEUTRAL
Operation
H-6
FINE CONTROL MODE DOES NOT FUNCTION
Failure information
Relative information
Cause
Travel speed
Lo
NEUTRAL
Hi
OPERATED
Orifice in LS circuit clogged The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
Improper adjustment or
malfunctioning of LS valve
1
Approx. 0.6 (Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment, malfunctioning of the LS valve or its internal
failure is suspected. In that case, check the valve itself.
4
Malfunctioning of servo
piston
PC400LC-7L
20-609 1
TROUBLESHOOTING
H-7
12
H-7
BOOM MOVES SLOWLY OR LACKS POWER
Failure information
Relative information
NEUTRAL
Boom RAISE
Boom LOWER
Travel lever
Neutral
Operated (Note)
Malfunctioning of merge/
divide valve (main and LS
valves)
The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve
itself.
Malfunctioning of boom
control valve (spool)
The spool in the boom control valve (Lo - Hi) is presumed to malfunction. Check the valve itself.
Malfunctioning of boom
control valve (pressure
compensation valve)
The pressure compensation valve in the boom control valve (Lo Hi) is presumed to malfunction. Check the
valve itself.
Malfunctioning of boom
control valve (regeneration
valve)
The regeneration valve in the boom control valve (Lo) or the seal is presumed to malfunction. Check the valve
itself.
Malfunctioning of boom
control valve (lock valve)
The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the valve itself.
The check valve in the boom control valve (Hi) is presumed to malfunction. Check the valve itself.
Malfunctioning of safety
valve for lock valve or
seal defective
The safety valve for the lock valve is presumed to malfunction, or the seal is suspected to be defective. Check
the valve itself.
10
Malfunctioning of boom
The suction valve (bottom side) in the boom control valve (Lo) is presumed to malfunction, or the seal is
control valve (suction valve) or suspected to be defective.
seal defective
11
Malfunctioning of boom
The safety and suction valves (head side) in the boom control valve (Lo) are presumed to malfunction, or the
control valve (safety and
seal is suspected to be defective. Check those valves themselves.
suction valves) or seal defective
12
Malfunctioning of LS shuttle
valve (left travel, bucket and
service valves)
LS shuttle valves in the left travel control valve, bucket control valve and service control valve are presumed to
malfunction. Check those valves themselves.
Boom cylinder
Raise relief
20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
20-610 1
PC400LC-7L
TROUBLESHOOTING
H-8
12
H-8
ARM MOVES SLOWLY OR LACKS POWER
Failure information
Relative information
NEUTRAL
Arm DIGGING
Arm DUMPING
Malfunctioning of merge/
divide solenoid valve
Travel lever
Neutral
Operated (Note)
Malfunctioning of merge/
divide valve (main and LS
valves)
Malfunctioning of arm control The generation valve in the arm control valve (Lo) is presumed to malfunction, or the seal is suspected to be
valve (regeneration valve)
defective. Check the valve itself.
Malfunctioning of arm control The safety and suction valves in the arm control valve (LoHi) are presumed to malfunction, or the seal is
valve (safety and suction
suspected of defect. Check those valves themselves.
valves) or seal defective
The quick return valve in the arm control valve (Hi) is presumed to malfunction. Check the valve itself.
Malfunctioning of LS shuttle
valve (right travel, boom, left
travel, bucket and service
valves)
LS shuttle valves in the right travel control valve, boom control valve, left travel control valve, bucket control
valve and service valve are presumed to malfunction. Check those valves themselves.
10
The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.
Digging relief
20 cc/min
Note: Operate the travel lever finely to a degree that the PPC oil pressure switch is turned ON.
PC400LC-7L
20-611 1
TROUBLESHOOTING
H-9
12
H-9
BUCKET MOVES SLOWLY OR LACKS POWER
Failure information
Relative information
NEUTRAL
Bucket DIGGING
Bucket DUMPING
The safety and suction valves in the bucket control valve are presumed to malfunction, or the seal is
suspected to be defective. Check those valves themselves.
The LS shuttle valve in the service control valve is presumed to malfunction. Check the valve itself.
The spool in the bucket control valve is presumed to malfunction. Check the valve itself.
Bucket cylinder
Digging relief
20 cc/min
H-10
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION
Work equipment does not move in its single operation
(1) The boom does not move when operated independently.
(2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.
Relative information
Failure information
Cause
Malfunctioning of work
equipment control valve
(spool)
20-612 1
NEUTRAL
Operated
The spool in the work equipment control valve is presumed to malfunction. Check the valve itself.
PC400LC-7L
TROUBLESHOOTING
H-11
12
H-11
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST
Failure information
Relative information
Cause
The seal at lock valve in the boom control lever is suspected to be defective. Check the valve itself.
The seal at the safety valve in the lock valve (Lo) is suspected to be defective. Check the valve itself.
Boom cylinder
Raise relief
20 cc/min
Relative information
Failure information
Cause
Arm cylinder
Digging relief
20 cc/min
The seal for safety and suction valves (bottom side) in the arm control valve (LoHi) is suspected to be
defective. Check the valve itself.
(Whether the seal is defective or not may well be determined by changing for other safety and suction
valves.)
The seal for spool in the arm control valve (LoHi) is suspected to be defective. Check the seal itself.
The seal for pressure compensation valve (bottom side) in the arm control valve
(LoHi) is suspected to be defective. Check the seal itself.
Relative information
Failure information
Cause
Bucket cylinder
Digging relief
20 cc/min
The seal for the safety and suction valves (bottom side) in the bucket control lever is suspected to be
defective. Check the seal itself.
(Whether the seal is defective or not may well be determined by changing for other safety and suction valves.)
The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.
The seal for pressure compensation valve (bottom side) in the bucket control valve is suspected to be
defective. Check the seal itself.
PC400LC-7L
20-613 1
TROUBLESHOOTING
H-12
12
H-12
WORK EQUIPMENT HAS BIG TIME LAG
The work equipment has a big time lag.
Relative information
Failure information
Cause
Travel speed
Lo
NEUTRAL
Hi
Operation
Malfunctioning of control
valves (safety & suction valve)
The safety and suction valves (boom : head side, arm and bucket : bottom side) of the control valve are presumed
to malfunction. Check those valves themselves directly.
(Whether they are defective or not may well be determined by changing them for other safety and suction valves.)
H-13
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT
Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information
Failure information
Cause
H-14
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK
One-touch power max. function does not work.
Relative information
Failure information
Cause
Malfunctioning of 2-stage
solenoid valve
Malfunctioning of main
relief valve
20-614 1
OFF
ON
The main relief valve of control valve is presumed to malfunction. Check the valve itself.
PC400LC-7L
TROUBLESHOOTING
H-15
12
H-15
MACHINE PUSH-UP FUNCTION DOES NOT WORK
Failure information
Relative information
Cause
Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting.
1
OFF
ON
0 MPa {0 kgf/cm2}
The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting side on the head
side) may be malfunctioning. Check it directly.
H-16
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD
MOVES SLOWLY
In a compound operation, work equipment with larger load tends to move slowly.
Relative information
---
Failure information
Cause
Malfunctioning of pressure
compensation valve for work
equipment with larger load
PC400LC-7L
Boom RAISE +
arm DIGGING
Boom
Arm
Boom RAISE +
arm DUMPING
Arm
Boom
Boom RAISE +
bucket DIGGING
Boom
Bucket
Arm DUMPING +
bucket DIGGING
Arm
Bucket
Boom LOWER +
arm DUMPING
Arm
Boom
20-615 1
TROUBLESHOOTING
H-17
12
H-17
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY
In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information
If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
Failure information
Cause
Malfunctioning of LS select valve The LS select valve of control valve is presumed to malfunction, or the seal is suspected to be defective.
or seal defective
Check the valve and seal themselves.
H-18
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY
In a compound operation of swing + travel, the travel speed drops sharply.
Relative information
If the travel speed is slow in the single operation of travel, carry out the H-20 check first.
Failure information
Cause
20-616 1
Malfunctioning of LS shuttle
valve (left travel and swing)
The LS shuttle valve in the left travel control valve or the swing control valve is presumed to malfunction.
Check both of them directly.
PC400LC-7L
TROUBLESHOOTING
H-19
12
H-19
MACHINE SWERVES IN TRAVEL
Failure information
Relative information
Cause
Operated to Forward
Operated to Reverse
Malfunctioning of self-pressure
decompression valve
Control lever
Improper adjustment or
malfunctioning of LS valve
1
Nearly equal pressure
Approx. 0.6
(Approx. 3/5)
Malfunctioning of travel
interlocking solenoid valve
NEUTRAL
Malfunctioning of travel
interlocking valve
The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
PC400LC-7L
Travel relief
The final drive is suspected of an internal failure. Check the inside of the final drive directly.
(An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat
or metal chip or dust contained in the drained oil.)
20-617 1
TROUBLESHOOTING
H-20
12
H-20
MACHINE TRAVELS SLOWLY
Failure information
Relative information
Cause
Malfunctioning of
2 self-pressure decompression
valve
Operated to Forward
Operated to Reverse
Travel speed
Lo
NEUTRAL
Hi
Operated
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
Malfunctioning of travel
5 control valve (pressure
compensation valve)
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of travel
control valve (suction valve)
Malfunctioning of LS shuttle
7 valve (bucket)
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
20-618 1
Travel relief
The final drive is suspected of an internal failure. Check the inside of the final drive directly.
(An internal failure in the final drive may well be determined by an abnormal noise from within, abnormal heat or
metal chip or dust contained in the drained oil.)
PC400LC-7L
TROUBLESHOOTING
H-21
12
H-21
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER
Failure information
Relative information
NEUTRAL
NEUTRAL
OPERATED
The merge/divide valve of control valve is presumed to malfunction. Check the valve itself.
Malfunction of travel
control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool itself.
The pressure compensation valve in the travel control valve is presumed to malfunction. Check the valve
itself.
The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.
10
The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal
itself.
11
The seal in the check valve of the travel motor is suspected to be defective. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the motors between forward
and reverse, or right and left.)
12
The seal in the check valve of the travel motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the motors between forward
and reverse, or right and left.)
PC400LC-7L
20-619 1
TROUBLESHOOTING
H-22
12
H-22
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN
PRESET SPEED.
Failure information
Travel speed does not shift, or it is slower or faster than preset speed.
Relative information
Monitoring [01500]
Lo
690mA
Fine control (to the extent that the
decelerator is released)
Mi
740mA
Hi
0 mA
Lo
NEUTRAL
Approx.
1.37 MPa {14 kgf/cm2}(0.0199 psi)
Hi
Operation
Malfunctioning of travel
speed solenoid valve
Travel speed
Lo
NEUTRAL
Hi
Operation
The travel motor is presumed to malfunction when shifting speed. Check the speed shifting portion directly.
H-23
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)
A track shoe does not turn (only on one side).
Relative information
Failure information
Cause
The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.
The safety valve seat in the travel motor is suspected of defect. Check the seat itself.
The check valve seat in the travel motor is suspected of defect. Check the seat itself.
20-620 1
Travel relief
The final drive is suspected of an internal failure. Check the inside of the final drive directly.
(A failure inside the final drive may well be determined by an abnormal noise from within,
abnormal heat generated or metal dust or chips contained in the drained oil.)
PC400LC-7L
TROUBLESHOOTING
H-24
12
H-24
MACHINE DOES NOT SWING
Failure information
Relative information
Malfunctioning of swing
holding brake solenoid valve
NEUTRAL
Swing operated
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
(holding brake)
Check it directly.
Improper adjustment or
malfunctioning of swing motor
(safety valve)
ON
Swing relief
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.
Swing relief
The swing machinery is suspected of an internal failure. Check the inside of the swing machinery directly.
(A failure inside the swing machinery may well be determined by an abnormal noise from within, abnormal
heat generated or metal dust or chips contained in the drained oil.)
Relative information
Failure information
Cause
NEUTRAL
Swing operated
The spool in the swing control valve is presumed to malfunction. Check the spool itself.
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
watching if there is any change.)
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
defective
watching the result.)
PC400LC-7L
20-621 1
TROUBLESHOOTING
H-25
12
H-25
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW
Failure information
Relative information
Cause
Malfunctioning of swing
The swing holding brake portion of the swing motor is presumed to malfunction.
Improper adjustment or
malfunctioning of swing motor
(safety valve)
ON
Swing relief
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to
malfunction, or suspected of an internal failure. Check the valve itself.
Swing relief
Failure information
Relative information
Cause
NEUTRAL
Swing operated
Malfunctioning of swing
control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve itself.
Malfunctioning of swing
control valve (pressure
compensation valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
watching the result.)
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
Swing motor (check valve) seal (Whether the seal is defective or not may well be determined by swapping the right and left check valves and
defective
watching the result.)
20-622 1
PC400LC-7L
TROUBLESHOOTING
H-26
12
H-26
EXCESSIVE OVERRUN WHEN STOPPING SWING
Excessive overrun when stopping swing.
(1) The work equipment overruns excessively when stopping swing.
Relative information
Failure information
Cause
Improper adjustment or
malfunctioning of swing motor
(safety valve)
ON
Swing relief
If the oil pressure does not return to normalcy even after the adjustment, the safety valve is presumed to malfunction, or suspected of an internal failure. Check the valve itself.
Swing relief
Failure information
Relative information
Cause
NEUTRAL
Swing operated
The PPC slow return valve is suspected of clogging. Check the valve itself.
(Whether the valve is clogged or not may well be determined by swapping the right and left valves and watching
the result.)
Malfunctioning of swing
control valve (spool)
The spool in the swing control valve is resumed to malfunction. Check the valve itself.
The seal in the suction valve of the swing motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the right and left suction valves and
watching the result.)
The seal in the check valve of the swing motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the right and left check valves and
watching the result.)
PC400LC-7L
20-623 1
TROUBLESHOOTING
H-27
12
H-27
THERE IS BIG SHOCK WHEN STOPPING SWING
There is a big shock caused when stopping a swing motion.
Relative information
Failure information
Cause
NEUTRAL
Swing operated
The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
(Whether the valve malfunctions or not may well be determined by swapping the right and left valves and
watching the result.)
H-28
THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING
There is a big abnormal noise caused when stopping a swing motion.
Relative information
Failure information
Cause
Malfunctioning of
backpressure valve
The safety valve in the swing motor is presumed to malfunction. Check the valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check the seal itself.
(Whether the seal is defective or not may well be determined by swapping the right and left valves and watching the
result.)
The swing machinery is suspected of an internal failure. Check the inside of the machinery itself.
(A failure inside the swing machinery may well be determined by monitoring abnormal noise, abnormal heat
generated or metal dust or chips contained in the drained oil.)
20-624 1
PC400LC-7L
TROUBLESHOOTING
H-29
12
H-29
SWING NATURAL DRIFT IS TOO BIG
Swing natural drift is too big.
(1) When the swing holding brake is activated.
Failure information
When the swing lock switch is ON position, or the swing holding brake release switch is in the normal position, the
swing brake is activated and the swing is fixed with a disc brake.
Set the working mode in A mode for troubleshooting.
Relative information
Cause
NEUTRAL
Swing operated
The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that
portion directly.
Failure information
Relative information
Cause
When the swing holding brake release switch is in the emergency condition, the swing brake is released and the
swing is retained only hydraulically.
Set the working mode in A mode for troubleshooting.
Standard value in normalcy and references for troubleshooting
The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.
The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself
directly.
The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.
The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.
The check valve seal in the swing motor is suspected of defect. Check the valve itself directly.
Swing motor (shockless valve) The shockless valve in the swing motor is suspected of malfunction or the seal is suspected of defect. Check the
malfunctioned or seal defective valve or seal itself directly.
PC400LC-7L
20-625 1
TROUBLESHOOTING
H-30
12
H-30
ATTACHMENT CIRCUIT DOES NOT CHANGE
When attachment is installed
Failure information
Relative information
If an attachment is installed, the service circuit changes according to the selected working mode as shown below.
1) In mode A or E: The double acting circuit is selected and the safety valve is set to the low pressure.
2) In mode B: The single acting circuit is selected and the safety valve is set to the high pressure.
Setting of the safety valve on only port B side is changed. Port A is always set to the low pressure.
Cause
Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
1
Working mode
Mode E or A
Mode B
Malfunction of service 3 control valve The safety valve of the service control valve (on port B side) may have a
(safety valve)
malfunction. Check it directly.
The attachment return selector valve may have a malfunction. Check it directly.
H-31
FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED
When attachment is installed
Failure information
Relative information
If an attachment is installed, the flow rate in the service circuit changes according to the selected working mode.
How to adjust the flow rate in modes A and E is different from that in mode B. For details, see OPERATION
MANUAL.
Cause
1
Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
2
20-626 1
Service pedal
In NEUTRAL
Operated
PC400LC-7L
30
PC400LC-7L
30-1 2
TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
TRAVEL MOTOR AND FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-65
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
EXPANSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
OPERATORS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
REVOLVING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-88
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-91
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
30-2 2
PC400LC-7L
TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-95
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL . . . . . . . . . . . . . . 30-96
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
TRAVEL PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
OPERATORS CAB GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-117
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118
FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-127
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
PC400LC-7L
30-3 2
MEMORANDUM
30-4 2
PC400LC-7L
12
Special tools that are deemed necessary for removal or installation of parts are listed.
List of the special tools contains the following kind of information.
1.
Necessity:
: Special tools which cannot be substituted, should always be used.
:Special tools which are very useful if available, can be substituted with commercially available tools.
2.
3.
REMOVAL OF PARTS
The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained.
Various symbols used in the REMOVAL Section are explained and listed below.
WARNING! This mark indicates safety-related precautions which must be followed when doing the
work.
INSTALLATION OF PARTS
Except where otherwise instructed, install parts is the reverse order of removal.
Instructions and precautions for installing parts are shown with [*1] mark in the INSTALLATION Section, identifying
which step the instructions are intended for.
Marks shown in the INSTALLATION Section stand for the following.
WARNING! This mark indicates safety-related precautions which must be followed when doing the
work.
PC400LC-7L
30-5 2
Various special tools are illustrated for the convenience of local manufacture.
30-6 2
PC400LC-7L
12
1.
2.
Nominal
number
02
07376-50210
03
07376-50315
04
07376-50422
05
07376-50522
06
07376-50628
10
07376-51034
12
07376-51234
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
PC400LC-7L
30-7 2
If the part is not under hydraulic pressure, the following corks can be
used:
Dimensions
Nominal
number
Part Number
06
07049-00608
08
07049-00811
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
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press-fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
30-8 2
PC400LC-7L
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.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS
To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
Do not use seal tape for the thread of the plug mounts or connections.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
D. After completing bleeding the air, tighten the plugs.
Plug: 11.3 1.5 Nm (8.33 1.10 lbf ft)
E. After repair or long storage, follow the same procedure.
PC400LC-7L
30-9 2
Q'ty
Puller
790-331-1110
Wrench
795-931-1100
Seal puller
795-931-1210
Push tool
Part No.
01050-31625
Bolt
01050-31645
Bolt
Push tool
795-931-1220
01050-31645
795T-521-1140
Engine assembly
A
6
30-10 2
B
C
790-101-5221
Grip
01010-81225
Bolt
01050-31640
Bolt
Remover
795-471-1810
Plate
795-471-1820
Bolt
795-471-1830
Bracket
01435-01035
Bolt
Bolt
Bolt
Push tool
795-471-1800
Engine and
hydraulic pump
assembly
Part Name
01435-01025
795T-471-1550
Wrench
796-601-1110
Stopper
796-460-1210
Oil stopper
Adapter
796-770-1320
Sketch
Necessity
795-799-1170
Symbol
Component
New/remodel
Remark
Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
Remark
Necessity: :............... Cannot be substituted, should always be installed (used)
:................Extremely useful if available, can be substituted with commercially available part
Remark
New/remodel: N:..........Tools with new part numbers, newly developed for this model
R:..........Tools with upgraded part numbers, remodeled from items already available for
other models
Blank:.... Tools already available for other models, used without any modification
Remark
Tools marked O in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
O
Press fitting of engine front seal
O
N
PC400LC-7L
Q'ty
Push tool
Removal of shaft
2 790-201-2350
Push tool
Removal of bearing
3 790-201-2510
Part No.
Push tool
790-101-5401
790-101-5531
Plate
790-101-5421
Grip
01010-51240
Bolt
Push tool
6 790-201-2770
Push tool
7 796T-626-1110
Push tool
796-627-1210
Wrench assembly
796-627-1220
Wrench
796-427-1140
Pin
01314-20612
Screw
790-101-2510
Block
791-122-1130
Plate
790-101-2550
Leg
Adapter
790-101-2570
Plate
790-101-2560
Nut
790-101-2102
790-101-1102
Pump
3 796-627-1020
Installer
791-430-3230
Installer
791-601-1000
Oil pump
791-630-1780
Installer
791-601-1000
Oil pump
791-575-1520
Installer
791-601-1000
Oil pump
791-685-8006
Compressor
791-635-3160
Extension
790-101-1600
790-101-1102
Pump
790-201-1500
790-201-1660
Plate
790-101-5021
Grip
01010-50816
Bolt
Idler assembly
J
2
PC400LC-7L
Push tool
2 790-101-2740
796T-627-1230
5 790-201-2870
Part Name
Sketch
Necessity
1 796T-627-1630
Symbol
Component
New/remodel
12
Supply of oil
1
Installation of dust seal
30-11 2
Remover and
installer
790-101-1300
Cylinder
(980 kN {100 t})
790-101-1102
Pump
796-946-1310
Guide 21.8
Part No.
Part Name
796-946-2110
Guide 20.9
Guide 20.6
Guide
Guide 21.6
(For 723-46-42800)
796-946-2120
Guide
(For 723-46-44100)
796-946-2220
Guide
Sleeve
Sleeve
(For 723-46-42800)
3
796-946-2130
Sleeve
(For 723-46-44100)
796-946-2230
Sleeve
30-12 2
(For 723-46-44100)
796-946-2210
Sketch
Component
New/remodel
Q'ty
791-650-3000
Symbol
Necessity
12
790-101-2501
Push puller
790-101-2510
Block
790-101-2520
Screw
791-112-1180
Nut
790-101-2540
Washer
790-101-2630
Leg
790-101-2570
Plate
790-101-2560
Nut
790-101-2650
Adapter
PC400LC-7L
790-102-4300
Wrench assembly
790-102-4310
Pin
Expander
796-720-1680
07281-01589
796-720-1690
07281-01919
790-201-1702
1 790-502-1003
2
3 790-720-1000
Hydraulic cylinder
assembly
790-201-1851
790-201-1861
790-101-5021
Grip
01010-50816
Bolt
Work equipment
assembly
PC400LC-7L
Part Name
Sketch
Part No.
New/remodel
Q'ty
Symbol
Component
Necessity
12
790-201-1500
790-101-5021
Grip
01010-50816
Bolt
790-201-1660
790-201-1670
790-201-1680
796-670-1100
Remover
796-670-1110
Sleeve
796-670-1120
Plate
796-670-1130
Screw
796-870-1110
Adapter
01643-33080
Washer
01803-13034
Nut
790-101-4000
790-101-1102
30-13 2
30-14 2
799-703-1110
799-703-1120
799-703-1400
793-498-1210
20Y-54-13180
Adapter
Sketch
799-703-1100
Part Name
New/remodel
799-703-1200
Part No.
Q'ty
Necessity
Component
Symbol
12
PC400LC-7L
OF SPECIAL TOOLS
Remark
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A6. Push tool
A8. Wrench
PC400LC-7L
30-15 2
30-16 2
PC400LC-7L
12
Obtain the correct removal tool according to the wire size used in
the connector.
2.
With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder wire
removal and may damage the connector or removal tool. Always
use the correct removal tool size for the wire gauge you are
servicing.
3.
In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting removal tool
into the grommet. Damage to the tool or connector may result.
4.
Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5.
If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
PC400LC-7L
30-17 2
INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number
20 AWG
20 AWG
14 AWG
14 AWG
12 and 14 AWG
12 and 14 AWG
8 and 10 AWG
8 and 10 AWG
6 AWG
6 AWG
Wire Inspection
After stripping insulation from wire, inspect wire strands for:
Corrosion, straightness and uniformity
Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
30-18 2
PC400LC-7L
1.
After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2.
3.
4.
5.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L
30-19 2
1.
2.
3.
4.
5.
For unused wire cavities, insert sealing plugs for full environmental
sealing.
30-20 2
PC400LC-7L
1.
2.
Pull the wedge lock straight out and save for reinstallation.
3.
4.
Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
PC400LC-7L
30-21 2
INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number
20 AWG
20 AWG
14 AWG
14 AWG
12 and 14 AWG
12 and 14 AWG
8 and 10 AWG
8 and 10 AWG
6 AWG
6 AWG
Wire Inspection
After stripping insulation from wire, inspect wire strands for:
Corrosion, straightness and uniformity
Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
30-22 2
PC400LC-7L
1.
After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2.
3.
4.
5.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
PC400LC-7L
30-23 2
1.
2.
Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3.
Push the contact terminal straight into the connector until a click
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4.
Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.
Remark
As the connector receptacle is shown - use the same procedures for
a plug.
30-24 2
PC400LC-7L
ENGINE
12
ENGINE
Remark
Removal, installation, disassembly and assembly of the following components, see the ENGINE SHOP
MANUAL.
AFTERCOOLER
ALTERNATOR
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE OIL COOLER
ENGINE REAR SEAL
FUEL INJECTION PUMP
NOZZLE HOLDER
NOZZLE TIP
STARTING MOTOR
THERMOSTAT
TURBOCHARGER
WATER PUMP
PC400LC-7L
30-25 2
RADIATOR
12
RADIATOR
REMOVAL
1.
2.
3.
Install stay (3) with bolt [1] and fix engine hood (2) vertically.
4.
5.
6.
30-26 2
PC400LC-7L
RADIATOR
12
7. Remove cover (12).
8.
9.
PC400LC-7L
30-27 2
RADIATOR
12
INSTALLATION
[*1]
Radiator hose clamps
(7): 3.3 0.49 Nm {0.3 0.05 kgm} (2.4 0.36 lbf ft)
(8): 4.4 0.49 Nm {0.49 0.05 kgm} (3.2 0.36 lbf ft)
(9), (13): 8.8 0.5 Nm {0.9 0.05 kgm} (6.4 0.3 lbf ft)
30-28 2
PC400LC-7L
12
2.
Remove plug (2) of the hydraulic oil cooler drain hose to drain the
hydraulic oil.
Before draining, open the hydraulic tank cap to release the
pressure in the tank. Then, drain the oil through the cooler hose.
3.
4.
Install stay (101) with bolt [1] and fix engine hood (100) vertically.
PC400LC-7L
30-29 2
12
5. Remove hydraulic oil cooler tube mount bolts (5) and (6).
6.
Remove right and left hydraulic oil cooler mount bolts (7).
7.
8.
9.
INSTALLATION
30-30 2
PC400LC-7L
12
796-601-1110
Stopper
796-460-1210
Oil stopper
796-770-1320
Adapter
Part No.
Part Name
Sketch
Qty
New/Remodel
Symbol
Necessity
SPECIAL TOOLS
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
WARNING! Lower the work equipment to the ground and stop the engine. Then, loosen the hydraulic
oil filler cap slowly to release the internal pressure of the hydraulic tank.
Put tags to the disconnected hoses and tubes to prevent a mistake in re-connecting them.
1.
2.
Remove the hydraulic tank strainer. Using tool C, stop the oil.
When not using tool C, remove the drain plug to drain the oil from
the hydraulic tank and piping.
Hydraulic tank: Approximately 335 L (88.5 gal)
3.
4.
5.
PC400LC-7L
30-31 2
E. Adjust the engine hood so that center hole A of stay (101) will be
at the bolt (102).
F.
Install stay (101) with bolt [1] and fix engine hood (100)
vertically.
6.
7.
8.
Disconnect fuel inlet hose (5) and fuel return hoses (6) and (7). [*3]
9.
Disconnect clamp (8) and radiator hoses (9), (10), and (11). [*4]
30-32 2
PC400LC-7L
12
12. Loosen adjustment bolt (15) and remove belt (16). [*5]
13. Remove air conditioner compressor assembly (17).
Move the air conditioner compressor assembly toward the control
valve top cover.
14. Disconnect fan (18).
Insert your hand through clearance A between the fan and the
radiator and remove the 6 fan mount bolts in order, turning the fan
with your foot.
15. Disconnect aftercooler hose (21) and heater hose (22). [*6]
PC400LC-7L
30-33 2
12
19. Disconnect the following 2 wiring connectors.
(26): ERO2 (Various sensors)
(27): ERO3 (Each injector and fuel supply pump)
20. Remove mount bolts (28) and bracket (29).
30-34 2
PC400LC-7L
26. Disconnect engine ground cable (46) from the rear of the hydraulic
pump.
27. Using tool B, remove 4 front and rear engine mount bolts (47). [*7]
PC400LC-7L
30-35 2
12
INSTALLATION
[*1]
Hose clamp: 9.8 0.5 Nm {0.1 0.05 kgm} (7.2 0.36 lbf ft)
[*2]
Clamp: 10.5 0.5 Nm {1.07 0.05 kgm} (7.7 0.36 lbf ft)
[*3]
Fuel hoses (5), (6), and (7): 14.8 - 19.6 Nm {1.5 - 2.0 kgm} (10.9 - 14.4 lbf ft)
[*4]
Radiator hoses:
(9): 3.3 0.49 Nm {0.3 0.05 kgm}(2.4 0.36 lbf ft)
(10): 4.4 0.49 Nm {0.45 0.05 kgm}(3.2 0.36 lbf ft)
(11), (24):8.8 0.5 Nm {0.9 0.05 kgm} (6.4 0.36 lbf ft)
[*5]
See TESTING AND ADJUSTING, Testing and adjusting air conditioner compressor belt tension or REMOVAL
AND INSTALLATION OF ENGINE FRONT SEAL in engine manual.
[*6]
Air aftercooler hose clamp: 10.8 1 Nm {1.1 0.1 kgm} (7.9 0.73 lbf ft)
[*7]
Engine mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (607 - 759.6 lbf ft)
Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
30-36 2
PC400LC-7L
SWING CIRCLE
12
SWING CIRCLE
REMOVAL
1.
2.
INSTALLATION
[*1]
Mating face of swing circle: Gasket sealant (LG-6)
PC400LC-7L
30-37 2
12
2.
Detach the swing motor and swing machinery assembly (6), using
forcing screw [1] after removing the mount bolts. [*1]
3.
Lift and remove swing motor and swing machinery assembly (6).
When lifting the swing motor and swing machinery assembly for
removal, do so slowly so that the hoses and other parts will not be
damaged.
Take good care, when lifting the assembly, until the spigot
joint portion is pulled out.
Swing motor and swing machinery assembly: 550 kg
(1,212 lb)
30-38 2
PC400LC-7L
12
INSTALLATION
[*1]
Mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (608 - 759 lbf ft)
PC400LC-7L
30-39 2
Push tool
790-201-2350
Push tool
790-201-2510
Push tool
790-101-5401
790-101-5531
Plate
790-101-5421
Grip
01010-51240
Bolt
D 4
Part Name
790-201-2870
Push tool
790-201-2770
Push tool
796T-626-1110
Push tool
Sketch
796T-627-1630
Part No.
New/Remodel
Qty
Symbol
Necessity
12
SPECIAL TOOLS
DISASSEMBLY
1.
Draining oil
Loosen the drain plug and drain the oil from the swing machinery
case.
Swing machinery case: Approximately 21 L (5.5 gal)
2.
3.
30-40 2
PC400LC-7L
12
4. No. 1 carrier assembly
A. Remove No. 1 carrier assembly (3).
5.
Ring gear
Remove the mount bolts and ring gear (10).
6.
PC400LC-7L
30-41 2
12
7. Bolt
Remove holder mount bolt (12).
8.
9.
Shaft assembly
A. Turn over case and pinion assembly (24) and remove 12 mount
bolts (23) of cover assembly (22).
30-42 2
PC400LC-7L
12
B. Turn over case and pinion assembly (24) and set it on the press
stand. Using push tool [2], D1 and the press, pull out pinion shaft
assembly (25).
Set a wood block under the press so that the pinion shaft will
not be damaged when it comes off.
A rough standard pressing force is 20 odd tons.
10. Disassemble the pinion shaft assembly (25) according to the following
procedure.
A. Using the push tool, remove cover assembly (22) and bearing (26)
from shaft (27).
A rough standard pressing force is 30 tons.
B. Remove oil seal (28) from cover (29).
11. Bearing
Using multiple push tools [3], remove bearing (30) from case (31).
Push tool to be set contact with bearing: D2
PC400LC-7L
30-43 2
12
ASSEMBLY
Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
1.
Bearing
Using push tool D3 and [4], press fit bearing (26) to case (31).
A rough standard pressing force is several tons.
2.
Cover assembly
A. Using push tool D4, press fit oil seal (28) to cover (29).
Periphery of oil seal: Gasket sealant (LG-6)
Take care that the gasket sealant (LG-6) will not stick to the
oil seal lip and shaft assembly (22).
B. Install cover assembly (22) to case (31) and tighten mount bolts
(23).
Match the oil path of cover (22) to the drilled hole of case
(31).
Cover fitting face: Gasket sealant (LG-6)
30-44 2
PC400LC-7L
Case assembly
A. Turn over case assembly (32) and set it to shaft (27). Using push
tools D5 and D6 [5], press fit the bearing inner race.
When setting the case assembly to the shaft, take care
extremely not to damage the oil seal.
A rough standard pressing force is 30 tons.
B. Bearing
Using too D7, press fit bearing (30).
Press both inner race and outer race of the bearing
simultaneously. Do not press only the inner race.
A rough standard pressing force is 20 odd tons.
After press fitting the bearing, check that the case turns
smoothly.
4.
ii.
Install bearing (19) to gear (18) and fit top and bottom thrust
washers (17) and (20), and then set the gear assembly to
carrier (16).
iii. Aligning the pin holes of shaft (15) and carrier, lightly hit the
shaft with a plastic hammer, etc. to install.
When installing the shaft, revolve the planetary gear and take
care not to damage the thrust washers.
iv. Insert pin (14).
PC400LC-7L
30-45 2
5.
Mount bolt:
343 - 427 Nm {34 - 43.5 kgm} (253 - 314 lbf ft)
B. Fit the O-ring to case (31).
6.
7.
Ring gear
Using the eyebolt (M12 x 1.75), install ring gear (10).
30-46 2
PC400LC-7L
12 When installing ring gear (10), set its match mark (part d) and
the projection of the case flange (part c) as shown in the at right
figure.
8.
Press fit shaft (5) to the carrier in the direction of the arrow
until the snap ring groove is seen.
ii.
After installing snap ring (4), press back the shaft from the
opposite side until the snap ring is fitted to face P of the
carrier. At this time, take care not to press back too much.
iii. After installing plate (9), install thrust washer (8), bearing (7),
gear (6), and snap ring (4).
PC400LC-7L
30-47 2
12
B. Install No. 1 carrier assembly (3).
9.
Take care not to install the No. 1 sun gear upside down.
Install the No. 1 sun gear with the tooth (part e) down.
30-48 2
PC400LC-7L
PC400LC-7L
30-49 2
SPROCKET
12
SPROCKET
REMOVAL
1.
2.
Swing work equipment 90, push up chassis with work equipment and
place block [1] between track frame and track shoe.
3.
INSTALLATION
[*1]
Thread of sprocket mount bolt:
Gasket sealant (LG-6)
Sprocket mount bolt:
640 - 785 Nm {65 - 80 kgm} (472 - 578 lbf ft)
30-50 2
PC400LC-7L
12
2.
3.
Disconnect drain hose (2), travel speed selector hose (3), and motor
hoses (4) and (5).
Remove the nipples, too.
4.
Remove the 24 mount bolts and lift off the final drive assembly (6).
[*1]
Take care extremely not to damage the nipple sealing faces of the
hose joints.
When slinging the final drive assembly, do not use the tap hole for
the cover.
Final drive assembly: 700 kg (1544 lb)
INSTALLATION
[*1]
Mount bolt: 490 - 608 Nm {50 - 62 kgm} (362 - 448 lbf ft)
PC400LC-7L
30-51 2
FINAL DRIVE
12
FINAL DRIVE
Wrench assembly
796-627-1220
Wrench
796-427-1140
Pin
01314-20612
Screw
796T-627-1230
Push tool
790-101-2510
Block
791-122-1130
Plate
790-101-2550
Leg
2 790-101-2740
Adapter
790-101-2570
Plate
790-101-2560
Nut
790-101-2102
790-101-1102
Pump
Installer
3 796-627-1020
Sketch
796-627-1210
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
SPECIAL TOOLS
DISASSEMBLY
1.
Draining oil
Remove the drain plug to drain the oil from the final drive case.
Final drive case: Approximately 11L (3 gal)
2.
Cover
A. Place the final drive on block [1] and remove the mount bolts and
cover (1).
B. Using eyebolt [2], remove cover (1).
30-52 2
PC400LC-7L
FINAL DRIVE
12
3. Spacer
Remove spacer (2).
4.
5.
i.
Push in pin (5) to drive out shaft (6) from carrier (7).
After removing the shaft, remove pin (5).
ii.
Remove thrust washer (8), gear (9), bearing (10), and thrust
washer (11).
PC400LC-7L
30-53 2
FINAL DRIVE
12
6. Thrust washer
Remove thrust washer (14).
7.
8.
i.
Push in pin (16) to drive out shaft (17) from carrier (18).
After removing the shaft, remove pin (16).
ii.
Nut
A. Remove lock plate (23).
30-54 2
PC400LC-7L
FINAL DRIVE
12
B. Using tool E1, remove nut (24).
9.
Hub assembly
A. Using eyebolts [3], remove hub assembly (25) from the travel
motor.
ii.
PC400LC-7L
30-55 2
FINAL DRIVE
12
iii. Remove bearings (28) and (29) from hub (32).
D. Using puller [4], remove bearing (34) and collar (33) together.
You can remove bearing (34) and collar (33) without using
puller [4] in some cases.
30-56 2
PC400LC-7L
FINAL DRIVE
12
ASSEMBLY
Clean the all parts and check them for dirt or damage. Coat their
sliding surfaces with engine oil before installing.
1.
Hub assembly
A. Using the push tool, press fit bearings (28) and (29) to hub (32).
D. Using tool E3, install floating seal (30) (which is hidden and not
seen behind tool E3) to travel motor (31).
Thoroughly degrease and dry the O-ring and O-ring fitting
surface of the floating seal before installing.
After installing the floating seal, check that its slant is less
than 1 mm.
After installing the floating seal, thinly apply engine oil to the
sliding surfaces.
PC400LC-7L
30-57 2
FINAL DRIVE
12
E. Using eyebolts [3], set hub assembly (25) to the travel motor.
Using the push tool, lightly hit the bearing to press fit it.
2.
Nut
Install the nut according to the following procedure.
A. Rotate the hub 2 - 3 turns.
B. Using tool E2, press the bearing inner race.
Pressing force: 29.4 - 38.3 kN {3.0 - 3.9 tons}
C. While the bearing is pressed, rotate the hub at least 5 turns in 1
direction.
D. Release the pressing force.
E. Press the bearing again.
Pressing force: 14.7 - 18.6 kN {1.5 - 1.9 tons}
F.
30-58 2
PC400LC-7L
FINAL DRIVE
12
J.
Using push-pull gauge [5], measure the rotating force of the hub
in its revolving direction on the motor case.
Rotating force: Max. 765 N {78 kg} (171.9 lbf)
The rotating force means the maximum force at the tangent to
the bolt circle at the beginning of rotation.
Mount bolt:
66.2 7.4 Nm {6.75 0.75 kgm} (48.8 5.4 lbf ft)
3.
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).
ii.
Aligning the pin holes of shaft (17) and carrier, lightly hit the
shaft with a plastic hammer, etc. to install.
When installing the shaft, revolve the planetary gear
and take care not to damage the thrust washers.
PC400LC-7L
30-59 2
FINAL DRIVE
12
B. Install No. 2 carrier assembly (15).
Install No. 2 carrier assembly (15) so that the 4 gear shaft
ends will be in the 4 hollows at the motor case end.
4.
Thrust washer
Install thrust washer (14).
5.
6.
30-60 2
Install bearing (10) to gear (9) and fit top and bottom thrust
washers (8) and (11), and then set the gear assembly to carrier
(7).
PC400LC-7L
FINAL DRIVE
12
ii.
Aligning the pin holes of shaft (6) and carrier, lightly hit the
shaft with a plastic hammer, etc. to install.
When installing the shaft, revolve the planetary gear
and take care not to damage the thrust washers.
7.
8.
Spacer
Install spacer (2).
9.
Cover
Using eyebolts [2], install cover (1) and tighten the mount bolts.
Cover mount face: Gasket sealant (LG-6)
PC400LC-7L
30-61 2
CARRIER ROLLER
12
CARRIER ROLLER
Only precautions for assembling the carrier roller assembly are
explained below.
2 791-601-1000
Oil pump
Part Name
Sketch
Installer
Part No.
New/Remodel
Qty
1 791-430-3230
Symbol
Necessity
SPECIAL TOOLS
ASSEMBLY
Floating seal
When installing the floating seal, thoroughly clean, degrease, and
dry the contact surfaces of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the floating seal contact
surfaces.
Be sure to use the installer F to insert the floating seal assembly in
the housing.
After installing the floating seal, check that its slant is less than 1
mm and its projection a is 5 - 7 mm.
Carrier roller
Using tool F, apply the standard pressure to the oil filler to check
the seal for air leakage.
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} (14.2 psi)
30-62 2
PC400LC-7L
CARRIER ROLLER
12
Using tool F, fill the carrier roller assembly with oil and tighten the
plug.
Carrier roller: 170 - 180 cc (EO30-CD)
PC400LC-7L
30-63 2
TRACK ROLLER
12
TRACK ROLLER
Only precautions for assembling the track roller assembly are explained below.
2 791-601-1000
Oil pump
Part Name
Sketch
Installer
Part No.
New/Remodel
Qty
1 791-630-1780
Symbol
Necessity
SPECIAL TOOLS
ASSEMBLY
Floating seal
When installing the floating seal, thoroughly clean, degrease, and dry the contact surfaces of the O-ring and floating
seal (hatched parts). Take care that dirt will not stick to the floating seal contact surfaces.
Be sure to use the installer G to insert the floating seal assembly in the housing.
After installing the floating seal, check that its slant is less than 1 mm and its projection a is 5 - 7 mm.
Track roller
Using tool G, apply the standard pressure to the oil filler to check
the seal for air leakage.
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} (14.2 psi)
Using tool G, fill the track roller assembly with oil and tighten the
plug.
30-64 2
PC400LC-7L
IDLER
12
IDLER
Installer
791-601-1000
Oil pump
Part Name
Sketch
791-575-1520
Part No.
New/Remodel
Qty
Necessity
Symbol
SPECIAL TOOLS
DISASSEMBLY
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 assembly (6).
Idler is filled with oil of 345 10 cc. Drain it or spread cloths to
soak it at this time.
4.
Remove floating seal (7) on the opposite side from idler (5) and shaft
and support assembly (6).
5.
Remove nut (8), pull out bolt (9), and then remove support (10) from
shaft (11).
PC400LC-7L
30-65 2
IDLER
12
6. Remove bushing (12) from idler (5).
ASSEMBLY
1.
2.
Fit the O-ring and install support (10) to shaft (11) with bolt (9) and
tighten nut (8).
3.
Using tool H, install floating seal (7) to idler (5) and shaft and support
assembly (6).
30-66 2
PC400LC-7L
IDLER
4.
5.
Similarly, using too H, install floating seal (4) to idler (5) and support
(3).
PC400LC-7L
30-67 2
IDLER
12 Coat the sliding surface of the floating seal with oil and take care
that dirt will not stick to it.
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.
30-68 2
PC400LC-7L
RECOIL SPRING
12
RECOIL SPRING
Compressor
791-635-3160
Extension
790-101-1600
Cylinder
(686 kN {70 t})
790-101-1102
Pump
790-201-1500
790-201-1660
Plate
790-101-5021
Grip
01010-50816
Bolt
Part No.
Part Name
Sketch
Qty
791-685-8006
Symbol
New/Remodel
Necessity
SPECIAL TOOLS
DISASSEMBLY
1.
2.
PC400LC-7L
30-69 2
RECOIL SPRING
12
ASSEMBLY
1.
2.
B. Install cylinder (7), collar (8), and yoke (6) to spring (5), and then
set them to tool J1.
Sliding parts of cylinder: Grease (G2-LI)
Install the piston assembly so that the position of the valve will be on outside.
Supply 320 cc of grease (G2-LI) to the cylinder, bleed air, and check that the grease flows out of the grease hole.
30-70 2
PC400LC-7L
TRACK SHOE
12
TRACK SHOE
791-650-3000
Remover and
installer
790-101-1300
Cylinder (980 kN
{100 t})
790-101-1102
Pump
Sketch
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
SPECIAL TOOLS
EXPANSION
1.
Start the engine and set the master pin to above the idler.
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]
WARNING! 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.
4.
5.
Move the master pin forward and set block [1] under the track shoe in
front of the idler.
6.
7.
Move the machine in reverse slowly to expand the track shoe. [*4]
PC400LC-7L
30-71 2
TRACK SHOE
12
INSTALLATION
[*1]
Mount bolt: Anti-seizure compound (MARUZEN MOLYMAX No. 2 or equivalent)
Mount bolt: Tighten the 4 bolts first to 392 39 Nm {40 4 kgm} (289 28 lbf ft). Check that the
mating faces are fitted, then retighten each bolt by 120 10.
[*2]
Adjust the tension of the track shoe. For detail, see TESTING
AND ADJUSTING, Testing and adjusting track shoe tension.
Lubricator: 58.8 - 88.3 Nm {6 - 9 kgm} (43.3 - 65.1 lbf ft)
[*3]
Using the tool, press fit the master pin so that its projection a
will be as follows.
Dimension a: 4.4 2 mm
Supply grease to the space between the bushing and
pin so that filling rate will be 100%. Grease: NIGUTAITE
LYK-2 manufactured by NIPPON GREASE CO., LTD.
or equivalent
30-72 2
PC400LC-7L
12
799-703-1100
799-703-1110
799-703-1120
799-703-1400
Part Name
Sketch
799-703-1200
Part No.
New/Remodel
Qty
Necessity
Symbol
SPECIAL TOOLS
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.
2.
3.
Connect tool Q to cap [1] and collect the air conditioner refrigerant.
4.
5.
6.
7.
PC400LC-7L
30-73 2
12
8. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20
(16), and K19 (17).
9.
15. Remove the 7 mount bolts and air conditioner unit assembly (27).
30-74 2
PC400LC-7L
12
INSTALLATION
[*1]
Apply compressor oil (ND-OIL8) to the threads of the refrigerant pipe joints and tighten each nut with double
spanner.
Hose clamp (M6 bolt): 8 - 12 Nm {0.8 - 1.2 kgm} (5.9 - 8.8 lbf ft)
Hose screw of M16 x 1.5: 12 - 15 Nm {1.2 - 1.5 kgm} (8.8 - 11.0 lbf ft)
Hose screw of M22 x 1.5: 20 25 Nm {2.0 2.5 kgm} (14.7 - 18.4 lbf ft)
Hose screw of M24 x 1.5: 30 35 Nm {3.0 3.5 kgm} (22.1 - 25.8 lbf ft)
PC400LC-7L
30-75 2
OPERATORS CAB
12
OPERATORS CAB
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.
2.
3.
4.
Remove clip (10) and disconnect cab wiring connectors M45 (11),
H08 (12), and H09 (13).
5.
6.
Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18).
7.
8.
Remove controller sub-plate (21) and incline it against the air conditioner.
30-76 2
PC400LC-7L
OPERATORS CAB
12
9. Remove cover (22) and floor mat (23).
PC400LC-7L
30-77 2
OPERATORS CAB
12
17. Take grommet (35) out of the right front of the cab.
18. Disconnect the windshield washer hose from (36).
19. Remove 4 mount bolts (37) and 5 mount bolts (38).
Check the types of the bolts.
In the initial period, 7 mount bolts (38) are used.
20. Using lever block [1], lift off operator's cab assembly (39).
Operator's cab assembly: 300 kg (662 lb)
21. When starting the engine while the operator's cab is removed (for
transportation, etc.), use the following brackets.
A. Bracket (41) for controller (40), Part No.: 208-53-13920
INSTALLATION
30-78 2
PC400LC-7L
MONITOR
12
MONITOR
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.
2.
INSTALLATION
PC400LC-7L
30-79 2
PUMP CONTROLLER
12
PUMP CONTROLLER
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.
2.
Disconnect pump controller wiring connectors C01 (4), C02 (5), and
C03 (6).
3.
INSTALLATION
30-80 2
PC400LC-7L
ENGINE CONTROLLER
12
ENGINE CONTROLLER
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.
2.
3.
4.
Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and
CB3 (5).
INSTALLATION
PC400LC-7L
30-81 2
REVOLVING FRAME
12
REVOLVING FRAME
REMOVAL
WARNING! Extend the arm and bucket fully, lower the work equipment to the ground, and set the
safety lock lever to the LOCK position.
1.
2.
3.
4.
5.
Remove plate (3) and pin (4) and lift off boom cylinder assembly (2).
Remove the boom cylinder on the opposite side similarly.
Boom cylinder assembly: 360 kg (794 lb)
30-82 2
PC400LC-7L
REVOLVING FRAME
12
6. Disconnect 7 hoses (5) (11).
(5): Center swivel joint (Port D) Swing motor (Port T)
(6): Center swivel joint (Port D) Hydraulic tank
(7): Center swivel joint (Port E) Solenoid valve
(8): Center swivel joint (Port B) Control
valve left travel (Port B2)
(9): Center swivel joint (Port D) Control
valve right travel (Port B5)
(10): Center swivel joint (Port A) Control
valve left travel (Port A2)
(11):Center swivel joint (Port C) Control
valve right travel (Port A5)
7.
Pull out pin (12) on the center swivel joint side and disconnect the lock
plate from the center swivel joint.
8.
Remove 29 mount bolts (13), leaving 3 each at the front and rear sides.
9.
10. Remove the remaining 6 bolts and lift off revolving frame assembly
(14). [*1]
WARNING! When removing the revolving frame
assembly, take care that it will not interfere with the center swivel joint assembly.
Revolving frame assembly: 10,000 kg (22,047 lb)
PC400LC-7L
30-83 2
REVOLVING FRAME
12
INSTALLATION
[*1]
Match the soft zone point (P) of the outer race and the soft zone point (S) of the inner race.
Mating face of swing circle: Gasket sealant (LG-6)
30-84 2
PC400LC-7L
COUNTERWEIGHT
12
COUNTERWEIGHT
REMOVAL
1.
2.
3.
INSTALLATION
[*1]
Threads of mount bolt: Adhesive (LT-2)
Mount bolt:
3,430 - 4,212 Nm {350 - 430 kgm} (2,530 - 3106 lbf ft)
[*2]
Installation and adjustment of counterweight
1) Adjust the level difference from the exterior parts (horizontal clearance) with shims.
Kinds of shim thickness: 0.5 mm, 1 mm
2) Insert the shims so that the clearance between the door and counterweight and that between the revolving frame
and counterweight will be 10 5 mm evenly.
PC400LC-7L
30-85 2
HYDRAULIC TANK
12
HYDRAULIC TANK
REMOVAL
1.
2.
3.
Open engine hood (2) and remove control valve top cover (3).
4.
5.
6.
7.
8.
9.
30-86 2
PC400LC-7L
HYDRAULIC TANK
12
10. Remove sensor (13).
11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily and remove 6 mount
bolts (15).
INSTALLATION
Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
PC400LC-7L
30-87 2
HYDRAULIC PUMP
12
HYDRAULIC PUMP
Oil stopper
796-770-1320
Adapter
Part Name
Sketch
796-460-1210
Part No.
New/Remodel
Qty
Necessity
Symbol
SPECIAL TOOLS
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
WARNING! Lower the work equipment to the ground
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
Put tags to the disconnected hoses and tubes to prevent a mistake in
re-connecting them.
1.
2.
Remove the hydraulic tank strainer. Using tool C, stop the oil.
When not using tool C, remove the drain plug to drain the oil from
the hydraulic tank and piping.
Capacity of hydraulic tank:
Approximately 335 L (88.5 gal)
3.
4.
5.
6.
7.
8.
30-88 2
PC400LC-7L
HYDRAULIC PUMP
12
9. Disconnect the following 2 pump wiring connectors.
(6): V22 (PC-EPC solenoid valve) Band color: Red
(7): V21 (LS-EPC solenoid valve) Band color: White
10. Disconnect the following 10 hoses and 1 tube.
(8): EPC basic pressure port hose (Band color: Yellow)
(9): Rear pump pressure input port hose (Band color: Red)
(10): Rear pump discharge port hose
(11): Front pump discharge port hose
(12): Drain port hose
(13): Front load pressure input port hose
(14): Rear load pressure input port hose (Band color: Red)
(15): Front pump pressure input port hose
(16): Pump suction port tube
PC400LC-7L
30-89 2
HYDRAULIC PUMP
12
INSTALLATION
[*1]
Hydraulic pump involute spline: Anti-friction compound (LM-G)
Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
30-90 2
PC400LC-7L
12
2.
3.
INSTALLATION
[*1]
Oil seal lip portion: Grease (G2-LI)
PC400LC-7L
30-91 2
CONTROL VALVE
12
CONTROL VALVE
REMOVAL
WARNING! Lower the work equipment to the ground
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank and
set the safety lock lever to the LOCK
position.
Put tags to the disconnected hoses and tubes to prevent a mistake in reconnecting them.
1.
2.
3.
Remove partition covers (3), (4), and (5) between the engine and
control valve.
4.
5.
6.
7.
8.
9.
30-92 2
PC400LC-7L
CONTROL VALVE
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).
After removing the hoses from ports B, remove port A3 tube (Boom
bottom side).
Remove port A4 hose (Swing motor port MB).
Disconnect port A5 hose (Swivel joint port C).
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).
15. Disconnect the following 6 right PPC hoses.
(30): Bucket DUMP (Hose band: Black)
(31): Left travel FORWARD (Hose band: Red)
(32): Boom LOWER (Hose band: Brown)
(33): Right SWING
(34): Right travel FORWARD (Hose band: Green)
(35): Arm IN (Hose band: Blue)
PC400LC-7L
30-93 2
CONTROL VALVE
12
16. Disconnect the following 3 control valve hoses.
Do not disconnect hose C.
(36): Port BP5 hose (To solenoid)
(37): Port PX2 hose
(38): Port TS hose
17. Sling control valve assembly (40) temporarily and remove 3 mount
bolts (39).
30-94 2
PC400LC-7L
CONTROL VALVE
12
INSTALLATION
PC400LC-7L
30-95 2
CONTROL VALVE
SEAL
Remark
Only precautions for assembling the pressure compensation valve assembly and control valve assembly
are explained below.
796-946-1310
Guide 21.8
796-946-2110
Guide 20.9
(For 723-46-44100)
796-946-2210
Guide 20.6
Guide
Guide 21.6
(For 723-46-42800)
796-946-2120
Guide
(For 723-46-44100)
796-946-2220
Guide
Sleeve
Sleeve
(For 723-46-42800)
796-946-2130
Sleeve
(For 723-46-44100)
796-946-2230
Sleeve
30-96 2
Sketch
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
SPECIAL TOOLS
1
1
1
1
1
1
1
1
1
1
1
PC400LC-7L
CONTROL VALVE
12
Since there many types of the pressure compensation valves, make a mark on each valve to indicate from where it was
removed.
1.
Remove piston (2), plug (3), and spring (4) from pressure
compensation valve (1).
2.
3.
4.
Set tool L1 to piston (2) and push it in with your hand slowly so that
seal (5) will expand evenly.
You may push in the seal to the flat part of the tool first, and then
install the tool to the piston and push in the seal further.
5.
Set tool L2 to piston (1) for other seal (3) and push it in with your hand
slowly so that seal (3) will expand evenly.
You may push in the seal to the flat part of the tool first, and then
install the tool to the piston and push in the seal further.
6.
Install correcting tool L3 to piston (1) for about 1 minute to fit seals
(2) and (3).
Check that the seal are not projected or broken.
7.
Fit plug (3) and spring (4) to piston (2) and assemble pressure
compensation valve (1).
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.
After assembling, push the piston with your hand and check that it
is returned by only the spring force.
PC400LC-7L
30-97 2
CONTROL VALVE
12
ASSEMBLY
Apply engine oil to the sliding surfaces of the parts before installing.
When installing spools (7) and (10) in the valve chamber, direct drilled
holes (8) and (11) toward cylinder ports (9) and (12).
Install filters (13) to the bottom of ports PLS1 and PLS2 as shown at
right.
30-98 2
PC400LC-7L
CONTROL VALVE
12
Control valve top and bottom covers
Mating faces of control valve top and bottom covers:
SEALEND 242 or equivalent
Use 2 washers (W2) each for only 2 places of the control valve
top cover.
Tighten the mount bolts of the control valve top and bottom covers in
the following order.
(A D C B)
Mount bolt of control valve top and bottom covers:
156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft)
Merge-divider valve
Mating face of merge-divider valve: SEALEND 242 or
equivalent
Tighten the mount bolts of the merge-divider valve similarly to those of the control valve covers.
Mount bolt of merge-divider valve:
156.9 - 176.5 Nm {16 - 18 kgm} (115.7 - 130.1 lbf ft)
Tighten the mount bolts of the boom Hi check valve, quick return valve, lock valve, and arm plate similarly to those of the
control valve covers.
Mount bolt of boom Hi check valve, quick return valve,
lock valve, and arm plate:
58.8 - 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft)
PC400LC-7L
30-99 2
CONTROL VALVE
12
Mount bolts of back-pressure valve, boom Hi check
valve, quick return valve, lock valve and arm plate: 58.8
- 73.6 Nm {6 - 7.5 kgm} (43.3 - 54.2 lbf ft)
30-100 2
PC400LC-7L
12
1.
Disconnect six hoses (1) through (6) between travel motor and center
swivel joint.
(1): Center swivel joint (T port) Left travel motor (T port)
(2): Center swivel joint (T port) Right travel motor (T port)
(3): Center swivel joint (B port) Left travel motor (PA port)
(4): Center swivel joint (D port) Right travel motor (PB port)
(5): Center swivel joint (A port) Left travel motor (PB port)
(6): Center swivel joint (C port) Right travel motor (PA port)
2.
3.
Pull out pin (16) on the side of center swivel joint and remove the jam
plate from the center swivel joint.
4.
5.
PC400LC-7L
30-101 2
12
INSTALLATION
[*1]
Install the center swivel joint facing in the direction shown in the diagram.
(The diagram shows the machine as seen from above)
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.
Bleeding air
Bleed the air from the travel motor. For details see TESTING AND
ADUSTING, Air Bleeding of Various Parts.
30-102 2
PC400LC-7L
Push puller
790-101-2510
Block
790-101-2520
Screw
791-112-1180
Nut
790-101-2540
Washer
790-101-2630
Leg
790-101-2570
Plate
790-101-2560
Nut
790-101-2650
Adapter
Sketch
790-101-2501
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
12
SPECIAL TOOLS
DISASSEMBLY
1.
2.
3.
Using tool M, pull out swivel rotor (4) and ring (3) from swivel shaft
(5).
4.
5.
Remove O-ring (7) and slipper seal (8) from swivel rotor (4).
ASSEMBLY
1.
Assemble slipper seal (8) and O-ring (7) to swivel rotor (4).
2.
3.
Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install.
Contact surface of rotor, shaft: Grease (G0-LI or G2-LI)
When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.
4.
5.
PC400LC-7L
30-103 2
12
ASSEMBLY
When installing pistons (8), apply grease to their outside and the
inside of the valve body holes.
Mount bolt of plate (5):
11.8 - 14.7 Nm {1.2 - 1.5 kgm} (8.7 - 10.8 lbf ft)
Sliding parts of joint (4): 2 - 4 cc of Grease (G2-LI)
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).
Joint (4): 39 - 49 Nm {4 - 5 kgm} (28.7 - 36.1 lbf ft)
Observe the tightening torque of the joint.
Contact parts of piston and disc (2): Grease 0.3 - 0.8 cc
(G2-LI)
Nut (1): 69 - 88 Nm {7 - 9 kgm} (51.8 - 64.9 lbf ft)
When installing disc (2), adjust the play to 0.5 - 3mm at 200 mm
from the turning center of the lever.
30-104 2
PC400LC-7L
12
ASSEMBLY
Sliding part of shaft (13) (4 8 cc), contact parts of lever (12) and piston (7), and contact part of pin of
lever (26) and plate (24) (0.3 0.8 cc): Grease (G2-LI)
Use the inserting jig described in KES.D.07177 to insert bushing (19).
Use the inserting jig described in KES.D.04025 to insert spring pin (25).
PC400LC-7L
30-105 2
HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
Qty
790-502-1003
790-102-4300
Wrench assembly
790-102-4310
Pin
790-720-1000
Expander
796-720-1680
07281-01589
796-720-1690
07281-01919
790-201-1702
790-201-1851
790-201-1861
790-201-1871
790-101-5021
Grip
01010-50816
Bolt
2
3
N
5
Part Name
790-201-1500
790-101-5021
Grip
01010-50816
Bolt
790-201-1660
790-201-1670
790-201-1680
Sketch
Part No.
New/Remodel
Symbol
Necessity
SPECIAL TOOLS
DISASSEMBLY
1.
30-106 2
PC400LC-7L
HYDRAULIC CYLINDER
12
D. Disassemble the piston rod assembly according to the following
procedure.
i.
PC400LC-7L
30-107 2
HYDRAULIC CYLINDER
12
iv. Remove plunger (5).
Perform this work for only the boom and arm cylinder.
v.
Perform this work for only the boom and arm cylinder.
2.
3.
30-108 2
PC400LC-7L
HYDRAULIC CYLINDER
12
ASSEMBLY
Take care not to damage the packings, dust seals, O-rings, etc.
Clean the all parts. After installing them, cover the piping ports and
pin holes to prevent dirt from entering.
Do not insert each backup ring forcibly, but warm it in water at 50 60C (122 - 140F) and then insert it.
1.
2.
PC400LC-7L
30-109 2
HYDRAULIC CYLINDER
12
3. Piston rod assembly
A. Set the piston rod to tool N1.
B. Install cylinder head assembly (7) to the piston rod.
C. Fit the O-ring and backup ring to collar (6), and then install them.
Perform this work for only the boom and arm cylinders.
D. Install plunger (5).
Perform this work for only the boom and arm cylinders.
E. Set plunger (10) to the piston rod. Install 11 balls (9) and secure
them with cap (8).
After installing the plunger, check that it has a little play at its
end.
F.
Tighten piston assembly (4). Then, using tool N2, tighten piston assembly (4) until the screw holes are aligned.
Remove the burrs from the threads with a file.
Go to D.
When replacing either or both of the rod and piston assembly
(4) with new ones.
Make a mark of the cushion plug position on the end of the
rod having the bottom cushion.
Using the tool, tighten piston assembly (4) until it reaches the
end of the rod.
Piston assembly:
294 29.4 Nm {30 3.0 kgm} (216 21.6 lbf ft)
30-110 2
PC400LC-7L
HYDRAULIC CYLINDER
12
iii. Make a screw hole to install screw (3).
Apply a drill to the V-groove of the threaded parts of piston (4) and rod (2) and make a hole.
When making a hole on the cylinder (arm cylinder) having the bottom cushion, make it around the cushion
plug.
Tap to be used
10.3
12 x 1.75
Tap drill hole
depth
Tapping
depth
Bucket/Boom
27
20
Arm
36
29
PC400LC-7L
30-111 2
HYDRAULIC CYLINDER
12
H. Tighten the mount bolts of cylinder head assembly (7).
Mount bolt:
Bucket: 530 78.5 Nm {54.0 8 kgm} (390 57.8 lbf ft)
Arm: 892 137 Nm {91.0 14 kgm}(657 101 lbf ft)
Boom: 530 78.5 Nm {54.0 8 kgm} (390 57.8 lbf ft)
I.
30-112 2
PC400LC-7L
WORK EQUIPMENT
12
WORK EQUIPMENT
Remover
796-670-1110
Sleeve
796-670-1120
Plate
796-670-1130
Screw
796-870-1110
Adapter
01643-33080
Washer
01803-13034
Nut
790-101-4000
790-101-1102
Sketch
796-670-1100
New/Remodel
Part Name
Qty
Part No.
Necessity
Symbol
SPECIAL TOOLS
REMOVAL
WARNING! Extend the arm and bucket fully, lower the
work equipment to the ground, and set
the safety lock lever to the LOCK position.
WARNING! See TESTING AND ADJUSTING,
Releasing residual pressure in hydraulic
circuit.
1.
2.
Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1]
3.
4.
PC400LC-7L
30-113 2
6.
Disconnect 3 arm cylinder hoses (7) and 2 bucket cylinder hoses (8).
Put oil stopper plugs and secure the hoses to the valve side with
ropes.
7.
8.
Remove cover (9), plate (10), and foot pin (11) to disconnect work
equipment assembly (12). [*3]
WORK EQUIPMENT
9.
30-114 2
PC400LC-7L
WORK EQUIPMENT
12
INSTALLATION
[*1]
Tighten the locknut so that clearance a between the plate and
nut will be 0.5 - 1.5 mm.
[*2]
Inside wall of bushing before assembling pin:
Anti-friction composition (LM-P)
Greasing after assembling pin: Grease (LM-G)
PC400LC-7L
30-115 2
12
1.
2.
3.
4.
5.
6.
7.
Among the panes of window glass on the 4 sides of the operator's cab, 4 panes (1) (4) are stuck. In this section, the
procedure for replacing the stuck glass is explained. When replacing front window glass (4), remove front window
assembly (5). (It is impossible to replace only the front window glass while the front window assembly is installed to the
operator's cab.)
For the procedure for replacing the front window assembly, see FRONT WINDOW.
30-116 2
PC400LC-7L
20Y-54-13180
Adapter
Part name
Part No.
Sketch
793-498-1210
Part No.
New/Remodel
Q'ty
Symbol
Necessity
12
SPECIAL TOOLS
Part name
Remarks
Yokohama M-300
Metal primer
Yokohama G-200
Glass primer
20Y-54-39850
Sikaflex 256HV
Adhesive
20Y-54-51531
REMOVAL
Remove the window glass to be replaced according to the following
procedure.
1.
Using seal cutter [1], cut the adhesive between broken window glass
(7) and operator's cab (metal sheet) (8).
PC400LC-7L
30-117 2
12
INSTALLATION
1.
Using a knife and scraper [5], remove the remaining adhesive and
both-sided adhesive tape from the metal sheets (glass sticking
surfaces) of the operator's cab.
Remove the adhesive and both-sided adhesive tape to a degree
that they will not affect adhesion of the new adhesive. Take care
not to scratch the painted surfaces. (If the painted surfaces are
scratched, adhesion will be lowered.)
(The figure to the right shows the operator's cab of a wheel
loader.)
2.
Remove oil, dust, dirt, etc. from the sticking surfaces of cab (8) and
window glass (9) with white gasoline.
If the sticking surfaces are not cleaned well, the glass may not be
stuck perfectly.
Clean the all black part on the back side of the window glass.
After cleaning the sticking surfaces, leave them for at least 5
minutes to dry.
(The figure to the right shows the operator's cab of a wheel
loader.)
3.
30-118 2
PC400LC-7L
12
C. Evenly apply paint primer to the surfaces to stick both-sided
adhesive tapes and the surfaces out of those surfaces on operator's
cab (8) which will be coated with the adhesive.
Paint primer: Yokohama M-300 or equivalent
PC400LC-7L
30-119 2
12
D. Evenly apply glass primer to the sticking surfaces of window
glass (9).
Glass primer: Yokohama G-200 or equivalent
4.
A. Stick both-sided adhesive tape (6) for right side window glass (1).
30-120 2
PC400LC-7L
B. Stick both-sided adhesive tape (6) for left side rear window glass
(2) as shown in the figure.
C. Stick both-sided adhesive tape (6) for door lower window glass
(3) as shown in the figure.
PC400LC-7L
30-121 2
12
D. Stick both-sided adhesive tape (6) for front window glass (4) as
shown in the figure.
5.
30-122 2
PC400LC-7L
6.
Apply adhesive.
Use Sikaflex 256HV adhesive
The using limit of the adhesive is 4 months after the date of
manufacture. Do not use the adhesive after this limit.
Keep the adhesive in a dark place where the temperature is below 25C (77F).
Never heat the adhesive higher than 30C (86F).
When reusing the adhesive, remove the all hardened part from the nozzle tip.
A. Break aluminum seal of the outlet of adhesive cartridge and install the nozzle.
B. Cut the tip of the adhesive nozzle (14) so that dimensions (q) and
(r) will be as follows.
Dimension (q): 10 mm
Dimension (r): 15 mm
PC400LC-7L
30-123 2
12
D. Remove the release tape of the both-sided adhesive tape on the
glass side.
E. Apply adhesive (15) to the outside of both-sided adhesive tape (6)
of the operator's cab.
30-124 2
PC400LC-7L
12
7. Install the window glass.
A. Install window glass (9), matching it to the lines of the positioning
tapes drawn in step 5.
Since the window glass cannot be removed and stuck again,
stick it very carefully.
Stick the glass within 5 minutes after applying the adhesive.
B. After sticking window glass (9), press all around it until it is stuck
to the both-sided adhesive tape.
Press the corners of the window glass firmly.
PC400LC-7L
30-125 2
12
8. Fix the window glass.
A. After installing right window glass (1) to the operator's cab, insert
stopper rubbers Y2 to 2 places (v) at the bottom of the glass to fix
the glass.
B. Using styrene foam blocks [9] and rubber bands [10], fix the
window glass and both-sided adhesive tape to fit them completely.
9.
After installing the window glass, remove the primer and adhesive
from the operator's cab and window glass.
Using white gasoline, wipe off the adhesive before it is dried up.
When cleaning the glass, do not give an impact to it.
30-126 2
PC400LC-7L
FRONT WINDOW
FRONT WINDOW
WARNING! Lower the work equipment to the ground
and stop the engine.
To replace the front window glass, the front window assembly must be removed from the operator'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 blocks (1) and (2) and right corner block (3). [*1]
3.
Remove left striker bolt (4), right striker bolt (5), left corner block
bracket, and right corner block bracket (7). [*2]
4.
Install left striker bolt (4) to the operator's cab again and tighten it
lightly.
This bolt will be used to hang the pull-up assist cable in step 8.
5.
6.
Lower the front window assembly carefully a little. Put out rollers (8) and (9) under the both sides of the front window
through the portion from which the corner blocks were removed in step 3 (the portion where the rail is open) and hold
them.
7.
Remove rollers (8) and (9) under the both sides of the front window.
PC400LC-7L
30-127 2
FRONT WINDOW
12
8. Remove left lower pin (10). [*3]
If left lower pin (10) is removed, plate (12) at the end of pull-up
assist cable (11) comes off.
Hang plate (12) on the left striker bolt.
WARNING! The return load of 58.8 N {6 kg} (13.2 lbf)
is applied to the rear of the operator's cab.
Accordingly, take care when removing left
lower pin (10) to disconnect pull-up assist
cable (11).
9.
Put out the bottom of front window assembly (13) through the rail
opening portion and lower it gradually.
30-128 2
PC400LC-7L
FRONT WINDOW
12
11. Twist front window assembly (13) to the right and left to remove both
upper rollers (14) and (15) from the rails, and then remove front
window assembly (13).
PC400LC-7L
30-129 2
FRONT WINDOW
12
INSTALLATION
Carry out installation in the reverse order to removal.
[*1] [*2]
Adjust opening and closing of the front window assembly according to
the following procedure.
1.
Open and close the front window to check that it does not interfere
with the rails and the rollers are not hitch.
2.
30-130 2
PC400LC-7L
FRONT WINDOW
12
3. Raise the front window assembly and fix it with the rear locks (on both
sides).
Check that the locks in the rear of the operator's cab are applied
securely.
4.
Install right corner block (3) and fix right corner block bracket (7) with
right striker bolt (5).
Tighten the striker bolt securely after adjusting it in step 6.
Install the right corner block so that there will be no level
difference at part (a).
Install the right corner block so that level difference (b) between
the rail and right corner block (3) at part PF will be 0 - 1.0 mm.
Check that the right corner block is not projected from the rail at
the rolling surface of the roller.
Secure roller clearance (c) at part PJ.
PC400LC-7L
30-131 2
FRONT WINDOW
12
5. Install left corner blocks (1) and (2) and secure left corner bracket (6)
with left striker bolt (4).
Tighten the striker bolt securely after adjusting it in step 6.
Install the left corner blocks so that there will be no level
difference at 2 part (d).
Secure roller clearance (e).
6.
Tighten left striker bolt (4) and right striker bolt (5) at roughly right
positions so that front window glass (18) will be fitted to cab-side trim
seal (19).
30-132 2
PC400LC-7L
FRONT WINDOW
12
7.
Open and close the front window assembly and check the working
condition of both locks (20) and (21).
A. If both locks do not work normally, move the striker bolts toward
the rear of the cab and tighten them again.
B. After moving the striker bolts, check the fitness of the front
window glass and cab-side trim seal which was checked in step 6.
C. Repeat the work in 1) and 2) until the fitness of the front window
and the working condition of both locks (20) and (21) are
acceptable, and then tighten the striker bolts.
8.
After adjusting the striker bolts, splash water heavily over the front window glass and check that the water does not leak
into the cab.
9.
PC400LC-7L
30-133 2
FRONT WINDOW
12
10. Adjust the front window stoppers.
A. After adjusting closing lock of the front window assembly in
step 9, check the contact of both front window stoppers (23).
B. If both stoppers (23) do not contact normally, adjust and fix them
at places where they contact normally.
30-134 2
PC400LC-7L
90
OTHERS
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
HYDRAULIC DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
HYDRAULIC DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
HYDRAULIC DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
HYDRAULIC DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
HYDRAULIC DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
HYDRAULIC DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
ELECTRICAL DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
ELECTRICAL DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
ELECTRICAL DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
ELECTRICAL DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
ELECTRICAL DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17 . . . . . . . . . . . . 90-35
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18 . . . . . . . . . . . . 90-37
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19 . . . . . . . . . . . . 90-39
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20 . . . . . . . . . . . . 90-41
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21 . . . . . . . . . . 90-43
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22 . . . . . . . . . . 90-45
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23 . . . . . . . . . . 90-47
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24 . . . . . . . . . . 90-49
PC400LC-7L
90-1
OTHERS
12
MEMORANDUM
90-2
PC400LC-7L
OTHERS
HYDRAULIC
12
HYDRAULIC
PC400LC-7L
90-3
OTHERS
HYDRAULIC
MEMORANDUM
90-4
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-5
OTHERS
HYDRAULIC
MEMORANDUM
90-6
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-7
OTHERS
HYDRAULIC
MEMORANDUM
90-8
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-9
OTHERS
HYDRAULIC
MEMORANDUM
90-10
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-11
OTHERS
HYDRAULIC
MEMORANDUM
90-12
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-13
OTHERS
HYDRAULIC
MEMORANDUM
90-14
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-15
OTHERS
HYDRAULIC
MEMORANDUM
90-16
PC400LC-7L
OTHERS
12
HYDRAULIC
PC400LC-7L
HYDRAULIC
90-17
OTHERS
HYDRAULIC
MEMORANDUM
90-18
PC400LC-7L
OTHERS
ELECTRICAL
12
ELECTRICAL
PC400LC-7L
90-19
OTHERS
ELECTRICAL
MEMORANDUM
90-20
PC400LC-7L
OTHERS
ELECTRICAL
PC400LC-7L
90-21
OTHERS
ELECTRICAL
MEMORANDUM
90-22
PC400LC-7L
OTHERS
12
ELECTRICAL
PC400LC-7L
ELECTRICAL
90-23
OTHERS
ELECTRICAL
MEMORANDUM
90-24
PC400LC-7L
OTHERS
ELECTRICAL
PC400LC-7L
90-25
OTHERS
ELECTRICAL
MEMORANDUM
90-26
PC400LC-7L
OTHERS
12
ELECTRICAL
PC400LC-7L
ELECTRICAL
90-27
OTHERS
ELECTRICAL
MEMORANDUM
90-28
PC400LC-7L
OTHERS
12
ELECTRICAL
PC400LC-7L
ELECTRICAL
90-29
OTHERS
ELECTRICAL
MEMORANDUM
90-30
PC400LC-7L
OTHERS
12
ELECTRICAL
PC400LC-7L
ELECTRICAL
90-31
OTHERS
ELECTRICAL
MEMORANDUM
90-32
PC400LC-7L
OTHERS
12
ELECTRICAL
PC400LC-7L
ELECTRICAL
90-33
OTHERS
ELECTRICAL
MEMORANDUM
90-34
PC400LC-7L
OTHERS
12
M
ELECTRICAL
PC400LC-7L
90-35
OTHERS
ELECTRICAL
MEMORANDUM
90-36
PC400LC-7L
OTHERS
12
M
ELECTRICAL
PC400LC-7L
90-37
OTHERS
ELECTRICAL
MEMORANDUM
90-38
PC400LC-7L
OTHERS
12
E CIRCUIT
PC400LC-7L
ELECTRICAL
90-39
OTHERS
ELECTRICAL
MEMORANDUM
90-40
PC400LC-7L
OTHERS
12
E CIRCUIT
PC400LC-7L
ELECTRICAL
90-41
OTHERS
ELECTRICAL
MEMORANDUM
90-42
PC400LC-7L
OTHERS
12
P CIRCUIT
PC400LC-7L
ELECTRICAL
90-43
OTHERS
ELECTRICAL
MEMORANDUM
90-44
PC400LC-7L
OTHERS
12
P CIRCUIT
PC400LC-7L
ELECTRICAL
90-45
OTHERS
ELECTRICAL
MEMORANDUM
90-46
PC400LC-7L
OTHERS
12
P CIRCUIT
PC400LC-7L
ELECTRICAL
90-47
OTHERS
ELECTRICAL
MEMORANDUM
90-48
PC400LC-7L
OTHERS
12
P CIRCUIT
PC400LC-7L
ELECTRICAL
90-49
OTHERS
ELECTRICAL
MEMORANDUM
90-50
PC400LC-7L