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CEBM012502

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

Copyright 2004 Komatsu


DataKom Publishing Division
00-1 2

FOREWORD
12

CONTENTS

CONTENTS

00

01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20

TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90

OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 2

PC400LC-7L

PRODUCT PUBLICATIONS INFORMATION


Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION

FORM NUMBER

PARTS BOOK - PAPER:


Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB040500

OPERATION AND MAINTENANCE MANUAL:


Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM012900

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

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS


COMPLETE FORM
AND RETURN TO

DataKom Publications and Training Division


440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887

COMPANY NAME
PURCHASE ORDER NO.

SHIP TO
ATTN.

TYPE or PRINT
ONLY

STREET ADDRESS

ORDER DATE

CITY, STATE, ZIP CODE


COUNTRY

PHONE NO.

FAX NO.

SHIPPING METHOD

DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY.

PUBLICATION FORM NO.

PARTS BOOK
P-Paper
M-Microfiche

KDC91E 071403

PUBLICATION
DESCRIPTION

MODEL NUMBER

CURRENT PRICES WILL BE CHARGED

SERIAL NUMBER

FOREWORD
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PC400LC-7L

FOREWORD

SAFETY

12

SAFETY

00

SAFETY NOTICE

00

IMPORTANT SAFETY NOTICE

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.

PREPARATIONS FOR WORK

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.

PRECAUTIONS DURING WORK

00

1.

When removing the oil filler cap, drain plug or


hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

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

HOW TO READ THE SHOP MANUAL

12

HOW TO READ THE SHOP MANUAL


VOLUMES

00

Shop manuals are issued as a guide to carrying out repairs.


They are divided as follows:
Chassis volume:
Engine volume:

Issued for every machine model


Issued for each engine series

00

REVISIONS

00

Revised pages are shown at the LIST OF REVISED PAGES


between the title page and SAFETY page.

SYMBOLS

00

Electrical volume: Each issued as one to cover all models


Attachment volume: Each issued as one to cover all models

So that the shop manual can be of ample practical use,


important places for safety and quality are marked with the
following symbols.

These various volumes are designed to avoid duplication of


information. Therefore to deal with all repairs for any model,
it is necessary that chassis, engine, electrical and attachment
be available.

Symbol

DISTRIBUTION AND UPDATING

1.
2.

Safety

Special safety precautions are


necessary when performing the
work.

Caution

Special technical precautions or


other precautions for preserving
standards are necessary when
performing the work.

Weight

Weight of parts or systems.


Caution necessary when
selecting hoisting wire or when
working posture is important,
etc.

Tightening
torque

Places that require special


attention for tightening torque
during assembly.

Coat

Places to be coated with


adhesives and lubricants etc.

Oil, water

Places where oil, water or fuel


must be added, and the capacity.

Drain

Places where oil or water must


be drained, and quantity to be
drained.

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

Any additions, amendments or other changes will be sent to


your distributors. Get the most up-to-date information before
you start any work.

FILING METHOD

Item

Additional pages: Additional pages are indicated by a


hyphen (-) and numbered after the page number. File as
in the example.
Example:

10-4
10-4-1
10-4-2

Added pages

10-5

REVISED EDITION MARK

00

When a manual is revised, an edition mark (123) is


recorded on the bottom outside corner of the pages.

00-6

PC400LC-7L

FOREWORD

HOISTING INSTRUCTIONS

12

HOISTING INSTRUCTIONS

00

HOISTING

can result. Hooks have maximum strength at the middle


portion.

00

WARNING! Heavy parts (25 kg or more)


must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol

1.
2.

If a part cannot be smoothly removed from the machine


by hoisting, the following checks should be made:
Check for removal of all bolts fastening the part to the
relative parts.
Check for existence of another part causing interface
with the part to be removed.

WIRE ROPES
1.

3.

WARNING! Slinging with one rope may


cause turning of the load during
hoisting, untwisting of the rope,
or slipping of the rope from its
original winding position on the
load, which can result in a
dangerous accident

00

Use adequate ropes depending on the weight of parts to


be hoisted, referring to the table below:

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.

Do not sling a heavy load with ropes forming a wide


hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
hoisting is made with two ropes, each of which is
allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
weight becomes 1000 kg when two ropes make a 120
hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
2000 kg load at a lifting angle of 150

The allowable load value is estimated to be 1/6 or 1/7 of


the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

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

Main applications, features

Used to prevent rubber gaskets, rubber cushions


and cork plugs from coming out

Used in places requiring an immediately


effective, strong adhesive.
Used for plastics (except polyethylene,
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.

Used as adhesive or sealant for metal, glass or


plastic.

Used as sealant for machined holes.

Used as heat-resisting sealant for repairing


engine.

Quick hardening type adhesive.


Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers,
plastics and woods.

Gasket sealant

00-8

790-129-9070

1 kg

Quick hardening type adhesive.


Quick cure type (max. strength after 30 minutes).
Used mainly for adhesion of rubbers, plastics
and metals.
Features: Resistance to heat, chemicals
Used at joint portions subject to high
temperature.

Used as adhesive or sealant for gaskets and


packing of power train case, etc.

Features: Resistance to heat


Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
seizure.
Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

LG-3

Features: Resistance to heat, chemicals


Used for anti-loosening and sealant purposes for
bolts and plugs.

Can

PC400LC-7L

FOREWORD
Category

Code

COATING MATERIALS
Part No.

Quantity

Container

Main applications, features

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

Used as sealant for various threads, pipe joints,


flanges.
Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Features: Silicon based, resistant to heat, cold.
Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case, etc.
Features: Silicon based, quick hardening type.
Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.

Used as heat-resisting sealant for repairing


engines.

Used as lubricant for sliding parts (to prevent


squeaking).

Used to prevent seizure or scuffing of the thread


when press fitting or shrink fitting.
Used as lubricant for linkage, bearings, etc.

G2-LI

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA160CNLI

Various

Various

General purpose type

G2-CA

SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYG2-160CNCA

Various

Various

Used for normal temperature, light load bearing


at places in contact with water or steam.

400 g (10 per


case)

Belows type

Used for places with heavy load.

Molybdenum
disulphide lubricant

Grease

Molybdenum
disulphide
lubricant

LG-7

Features: Resistance to water, oil


Used as sealant for flange surface, thread.
Also possible to use as sealant for flanges with
large clearance.
Used as sealant for mating surfaces of final drive
case, transmission case.

PC400LC-7L

SYG2-400M

00-9

FOREWORD

STANDARD TIGHTENING TORQUE

12

STANDARD TIGHTENING TORQUE

00

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

00

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.

Thread diameter of bolt

Width across flats

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

Thread diameter of bolt

Width across flats

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

STANDARD TIGHTENING TORQUE

TORQUE OF HOSE NUTS

00

Use these torques for hose nuts.


Thread diameter

Width across flat

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

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

00

Use these torques for split flange bolts.


Thread diameter

Width across flat

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

TIGHTENING TORQUE FOR FLARED NUTS

00

Use these torques for flared part of nut.

Thread diameter

Width across flat

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

ELECTRIC WIRE CODE

12

ELECTRIC WIRE CODE

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

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

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

CLASSIFICATION BY COLOR AND CODE

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

White & Red

Black &
White

Green &
White

Blue & White

Code

WB

BY

RB

YB

GR

LR

Color

White &
Black

Black &
Yellow

Red & Black

Yellow &
Black

Green & Red

Blue & Red

Code

WL

BR

RY

YG

GY

LY

Color

White & Blue

Black & Red

Red &
Yellow

Yellow &
Green

Green & Yellow

Blue &
Yellow

Code

WG

RG

YL

GB

LB

Color

White &
Green

Red & Green

Yellow &
Blue

Green &
Black

Blue & Black

Code

RL

YW

GL

Color

Red & Blue

Yellow &
White

Green & Blue

Red & White Yellow & Red

PC400LC-7L

FOREWORD

CONVERSION TABLES

12

CONVERSION TABLES

00

METHOD OF USING THE CONVERSION TABLE

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.

Convert 550 mm into inches.


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

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

Liter to U.S. Gallon

1 L = 0.2642 U.S. Gal


0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

Liter to U.K. Gallon

1 L = 0.21997 U.K. Gal


0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.699

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

PC400LC-7L

00-15

FOREWORD

CONVERSION TABLES

12

kgm to ft. lb.

00-16

1 kgm = 7.233 ft. lb.


0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.63

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)

D Track shoe width (Variable gauge)


D Track shoe width (Fixed gauge)
E Height of cab
F Radius of upper structure
G Overall length of track
H Length of track on ground
Min. ground clearance
Traveling speed (low/middle/high)
Swing speed
Tg Track gage
Tg (for transport)

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

Fixed gauge spec.

Variable gauge spec.

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)

12,040 (39 6")


3,640 (11 11")
----3,635 (11 11")
3,265 (10 9")
1,320 (4 4")
555 (1 10")
3,645 (12 0")
4,735 (15 6")
9,210 (30 3")
4,020 (13 2")
2,740 (9 0)
--3,265 (10 9")

12,040 (39 6")


3,690 (12 1")
3,192 (10 6")
3,690 (12 1")
3,635 (11 11")
3,265 (10 9")
1,320 (4 4")
685 (2 3")
3,645 (12 0")
4,735 (15 6")
9,210 (30 3")
4,020 (13 2")
2,890 (9 6")
2,392 (7 10")
3,265 (10 9")

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

The "Mi" mode is on the multi-monitor specification machine only.

PC400LC-7L

01-5

GENERAL

SPECIFICATIONS

Carrier roller

2 on each side

Track roller

8 on each side

Track shoe

Assembly-type triple grouser, 49 on each side

Hydraulic pump
Control valve

HPV190+190, variable displacement, piston type x2

Type x No.

Type x No.

Hydraulic motor

Hydraulic system

Undercarriage

12

Travel motor

KMV200ADT-2, Variable displacement, piston type (with


brake valve, parking brake): x 2

Swing motor

KMF230ABE-5, Fixed displacement piston type (with safety


valve, holding brake, reverse rotation
preventive valve): x 1

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")

Closed box type


Tank return side
CF40-1 (Air cooled)

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)

Radiator, oil cooler assembly

195 (430)

Hydraulic tank, filter assembly (excluding hydraulic oil)

198 (437)

Fuel tank (excluding fuel)

251 (554)

Revolving frame

3,297 (7,269)

Operators cab

279 (616)

Operators seat

35 (78)

Counterweight

9,500 (20,944)

Swing machinery (including swing motor)

526 (1,160)

Control valve (with service valve0

257 (567)

Swing motor

105 (232)

Travel motor

208 (459) x 2

Center swivel joint

Track frame assembly


Track frame

Center frame
Crawler frame

Swing circle
Idler
Idler cushion
Carrier roller
Track roller
Final drive (including travel motor)

40 (89)
Fixed gauge specification

Variable 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

Track shoe assembly

Standard triple grouser shoe (600 mm)


Standard triple grouser shoe (700 mm)
Wide triple grouser shoe (800 mm)
Wide triple grouser shoe (900 mm)

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)

Boom cylinder assembly

355 (783) x 2

Arm cylinder assembly

PC400LC-7L

510 (1,125)

01-7

GENERAL

WEIGHT TABLE

Bucket cylinder assembly

280 (618)

Link assembly

258 (569)

Boom pin
Arm pin

92 (203) + 20 (45) x 2 + 73 (161) + 27 (60) + 54 (120)


17 (38) + 23 (51)

Bucket pin

38 (102) x 2

Link pin

34 (75) x 2

01-8

PC400LC-7L

GENERAL

FUEL COOLANT AND LUBRICANTS

12

FUEL COOLANT AND LUBRICANTS


It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your distributor. The specified
fuel, coolant and lubricants recommended for this machine are as shown in the following table.

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)

Track roller (1 each)

0.28-0.31 (0.0739-0.0818)

Carrier roller (1 each)

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

ASTM D975 No. 1


For the H-046-HM, use the oil recommended by Komatsu.

PC400LC-7L

01-9

GENERAL

FUEL COOLANT AND LUBRICANTS

12

MEMORANDUM

01-10

PC400LC-7L

10

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

TABLE OF CONTENTS

BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132


WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
DIMENSION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
DIMENSION OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
OPERATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
STOPPING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
COMPONENTS OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
ELECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
CONTROL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
TOTAL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
ENGINE AND PUMP CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
PUMP/VALVE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION . . . . . . . . . . . . . . . . . . . . . . 10-158
AUTO-DECELERATION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
SWING CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
TRAVEL CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT) . . . . . . . . . . . . . . . . . . 10-168
SYSTEM COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
ENGINE REVOLUTION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
PPC OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
PUMP PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
MONITOR CONTROL, DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
MONITOR PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
MONITOR ITEMS AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
SELECT MODE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
MAINTENANCE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-189
SERVICE METER CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
DISPLAY LCD CHECK FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
ENGINE OIL LEVER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196

10-2

PC400LC-7L

STRUCTURE AND FUNCTION

RADIATOR OIL COOLER AFTERCOOLER

12

RADIATOR OIL COOLER AFTERCOOLER

1.

Oil cooler

7.

Radiator inlet hose

Specifications

2.

Radiator

8.

Radiator outlet hose

Radiator: ALW-4

3.

Radiator cap

9.

Aftercooler

Oil cooler: CF40-1

4.

Reservoir tank

10. Condenser

5.

Net

11. Fuel cooler

6.

Shroud

PC400LC-7L

10-3

STRUCTURE AND FUNCTION

POWER TRAIN

12

POWER TRAIN

1.

10-4

Idler

7.

Hydraulic pump (HPV190+190)

2.

Center swivel joint

8.

Travel speed solenoid valve

3.

Control valve

9.

Swing brake solenoid valve

4.

Final drive

10. Swing machinery

5.

Travel motor (KMV 200ADT-2)

11. Swing motor (KMF230ABE-5)

6.

Engine (SAA6D125-3E)

12. Swing circle

PC400LC-7L

STRUCTURE AND FUNCTION

FINAL DRIVE

12

FINAL DRIVE

PC400LC-7L

10-5

STRUCTURE AND FUNCTION

FINAL DRIVE

12
1.

Level plug

2.

Drain plug

3.

No. 1 planetary gear (No. of teeth: 43)

4.

No. 1 sun gear (No. of teeth: 10)

5.

No. 2 sun gear (No. of teeth: 18)

6.

No. 1 planetary carrier

7.

No. 2 planetary carrier

8.

Cover

9.

Ring gear (No. of teeth: 98)

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

Backlash between No. 1 sun gear and No. 1 planetary


gear

Standard clearance

Clearance limit

0.15 - 0.54

1.10

15

Backlash between No. 1 planetary gear and ring gear

0.18 - 0.66

1.30

16

Backlash between No. 2 planetary carrier and motor

0.06 - 0.24

---

17

Backlash between No. 2 sun gear and No. 2 planetary


gear

0.15 - 0.51

1.00

18

Backlash between No. 2 planetary gear and ring gear

0.17 - 0.60

1.20

19

Backlash between No. 2 planetary carrier and No. 2


sun gear

0.15 - 0.54

---

20

Amount of wear on sprocket tooth

21

Width of sprocket tooth

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

STRUCTURE AND FUNCTION

SWING MACHINERY

12

SWING MACHINERY

PC400LC-7L

10-7

STRUCTURE AND FUNCTION

SWING MACHINERY

12
1.

Swing pinion (No. of teeth: 13)

2.

Cover

3.

Case

4.

No. 2 planetary gear

5.

No. 2 sun gear

6.

Ring gear

7.

No. 1 sun gear

8.

Swing motor

9.

Oil level gauge

10. No. 1 planetary gear


11. No. 1 planetary carrier
12. No. 2 planetary carrier
13. Drain plug
Specification
Reduction ratio:
((19 +68)/19)x((16+68)/16)=24.039

Unit: mm
No.

Check item

Criteria

Remedy

Standard clearance

Clearance limit

0.18 - 0.28

---

14

Backlash between swing motor shaft and No. 1


sun gear

15

Backlash between No. 1 sun gear and No. 1


planetary gear

0.15 - 0.51

1.00

16

Backlash between No. 1 planetary gear and ring


gear

0.17 - 0.60

1.10

17

Backlash between No. 1 planetary carrier and


No. 2 sun gear

0.40 - 0.75

1.20

18

Backlash between No. 2 sun gear and No. 2


planetary gear

0.16 - 0.55

1.00

19

Backlash between No. 2 planetary gear and ring


gear

0.17 - 0.60

1.10

20

Backlash between coupling and swing pinion

0.08 - 0.25

---

21

Backlash between swing pinion and swing circle

0.00 - 1.21

2.00

22

Clearance between plate and coupling

0.57 - 1.09

---

23

Wear of swing pinion surface contacting with oil


seal

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

Apply hard chrome


plating, recondition, or
replace

PC400LC-7L

STRUCTURE AND FUNCTION

SWING CIRCLE

12

SWING CIRCLE

1.

Swing circle inner race (No. of teeth: 84)

Specification

2.

Ball

Reduction ration: - 84 = -6.462


13

3.

Swing circle outer race

Amount of grease: 33 L (8.71 gal) {G2-LI}

a.

Inner race soft zone S position

b.

Outer race soft zone S position

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

STRUCTURE AND FUNCTION

TRACK FRAME AND RECOIL SPRING

12

TRACK FRAME AND RECOIL SPRING

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

STRUCTURE AND FUNCTION

TRACK FRAME AND RECOIL SPRING

12
Item

Fixed gage

Variable gage

Shoe width

900 mm

800 mm

Link pitch

228 mm

228 mm

49 (Pieces)

49 (Pieces)

No. on track (one side)

Unit: mm
No.

10

11

Check item

Vertical width of idler guide

Horizontal width of idler guide

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 Rebuild or replace

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

STRUCTURE AND FUNCTION

IDLER

12

IDLER

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

704

---

Outside diameter of protruding

Outside diameter of tread

660

648

Depth of tread

22

28

Total width

202

---

Width of tread

48.5

---

Standard size
6

Clearance between shaft and bushing


95
Standard size

Interference between idler and bushing


102.6

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

STRUCTURE AND FUNCTION

CARRIER ROLLER

CARRIER ROLLER

Unit: mm
No.

Check item

Criteria
Standard size

Remedy
Repair limit

Outside diameter of flange

175

---

Outside diameter of tread

148

134

Width of tread

50.3

---

Thickness of tread

32

25

Width of flange

19

7
8

Interference between shaft and bushing

Interference between roller and bushing


Axial clearance of roller

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

STRUCTURE AND FUNCTION

TRACK ROLLER

12

TRACK ROLLER

10-14

PC400LC-7L

STRUCTURE AND FUNCTION

TRACK ROLLER

12

Unit: mm
No.

Check item

Criteria

Remedy

Standard size

Repair limit

240

---

237

---

Outside diameter of outer flange

Outside diameter of inner flange


(double flange)

Outside diameter of tread

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

Width of inner flange (Double


flange)

Axial play

10

Clearance between shaft and


bushing

11

Interference between roller and


bushing

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

STRUCTURE AND FUNCTION

TRACK SHOE

12

TRACK SHOE

P portion shows the link of bushing press-fitting end.

10-16

PC400LC-7L

STRUCTURE AND FUNCTION

TRACK SHOE

12
Unit: mm
No.
1

Check item
Link pitch

Bushing outside diameter

Thickness of bushing metal

Link height

Thickness of link metal (bushing press-fitting


portion)

6
7

Shoe bolt pitch

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

Protrusion of regular bushing

5.25

14

Overall length of pin

252

15

Overall length of bushing

16

Thickness of spacer

17
18

Remedy

184

8
10

Criteria

Press-fitting force

19

Repair or replace

Adjust or replace

164.5
---

Bushing

118 - 304 kN {12 - 31 ton}

Regular pin

176 - 451 kN {18 - 46 ton}

Master pin

137 - 284 kN {14 - 29 ton}

---

: Dry type track link

PC400LC-7L

10-17

STRUCTURE AND FUNCTION

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}

---

No. of shoes (each side)

22

23

Interference between bushing and


link
Interference between regular pin
and link
Clearance between regular pin and
bushing

Interference between master pin


and bushing

Standard size

Clearance between master pin and


bushing

---

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

Tightening torque Additinal tightening Lower limit torque


(Nm {lbf ft})
angle (deg.)
(Nm {lbf ft})
---

21

Remedy

Additinal tightening angle


(deg.)

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

STRUCTURE AND FUNCTION


12
TRIPLE

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

PC400LC-7L

10-21

STRUCTURE AND FUNCTION


12
HYDRAULIC

HYDRAULIC SYSTEM

TANK

1.

Oil filler cap

Specifications

2.

Breather

Tank capacity: 335 L (88.4 gal)

3.

Hydraulic tank

Amount of oil inside tank: 248 L (65.5 gal)

4.

Sight gauge

Pressure valve

5.

Strainer

Relief cracking Pressure: 0.17 0.07 kg/cm2 (2.47 0.99 psi)

6.

Filter element

Suction cracking pressure: 0 - 0.005 kg/cm2 (0 - 0.071 psi)

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

MEMORANDUM

PC400LC-7L

10-23

STRUCTURE AND FUNCTION


12
HYDRAULIC

HYDRAULIC SYSTEM

PUMP

HPV160+160(190)

1. Front main pump

IM

: PC mode selector current

PENR

: Rear pump control pressure detection port

2. Rear main pump

ISIG

: LS set selector current

PLSF

: Front load pressure input

3. LS valve

PAF

: Front pump delivery

PLSFC

: Front load pressure detection port

4. PC valve

PFC

: Front pump delivery pressure


detection

PLSR

: Rear load pressure input

5. LS-EPC valve

PAR

: Rear pump delivery

PLSRC

:Rear load pressure detection port

6. PC-EPC valve

PRC

: Rear pump delivery pressure


detection

PS

: Pump suction

7. Variable volume valve

PBF

: Front pump pressure input

PLSCR:

: LS set selector pressure detection port

PD1F

: Case drain port

PM

: PC set selector pressure detection port

PENF

: Front pump control pressure detection PEPC

: EPC basic pressure input

PBR

: Rear pump pressure input

PDIR

: Air bleeder

PD2F

: Drain plug

PEPB

: EPC basic pressure detection port

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

1.

Shaft (Front)

4.

Rocker cam

7.

Cylinder block

10. Shaft (Rear)

2.

Cradle

5.

Shoe

8.

Valve plate

11. Case (Rear)

3.

Case (Front)

6.

Piston

9.

End cap

12. Servo piston

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
LS

HYDRAULIC SYSTEM

VALVE

1. Plug

PA

: Pump port

2. Locknut

PP

: Pump port

3. Sleeve

PDP

: Drain port

4. Spring

PLP

: LS control pressure output port

5. Seat

PLS

: LS pressure input port

6. Spool

PPL

: PC control pressure input port

7. Piston

PSIG

: LS mode selection pilot port

8. Sleeve

PC VALVE

1. Servo piston assembly

PA

: Pump port

2. Plug

PA2

: Pump pressure pilot port

3. Pin

PDP

: Drain port

4. Spool

PM

: PC mode selector pressure pilot port

5. Retainer

PPL

: PC control pressure output port

6. Seat
7. Cover
8. Wiring

PC400LC-7L

10-29

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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).

Before the engine is started, servo piston (12) is pushed to


the right. (See the diagram on the right)
When the engine is started and the control lever is at the
neutral position, LS pressure PLS is 0 kg/cm2 (0 psi). (It is
interconnected with the drain circuit through the control
valve spool.)
At this point, spool (6) is pushed to the right, and port C and
port D are connected. Pump pressure PP enters the large
diameter end of the piston from port K and the same pump
pressure PP also enters port J at the small diameter end of the
piston, so the swash plate is moved to the minimum angle by
the difference in the area of the piston (12).

PC400LC-7L

10-31

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

B. Operation in increase direction for pump discharge amount


When the difference between the main pump pressure PP and LS pressure PLS, in other words, LS differential
pressure PLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and
pump PP drops), spool (6) is pushed to the left by the combined force of LS pressure PLS and the force of spring
(4).
When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC
valve is connected to the drain port, so circuit D K becomes drain pressure PT. (The operation of the PC valve
is explained later).
For this reason, the pressure at the large diameter end of servo piston (12) becomes drain pressure PT, and pump
pressure PP enters port J at the small diameter end, so servo piston (12) is pushed to the right. Therefore, the
swash plate moves in the direction to make the discharge amount larger. If the output pressure of the EPC valve
for the LS valve enters port G, this pressure creates a force to move piston (7) to the right. If piston (7) is pushed
to the right, it acts to make the set pressure of spring (4) weaker, and the difference between PLS and PP changes
when ports D and E of spool (6) are connected.

10-32

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

C. Operation in decrease direction for pump discharge amount


The following explains the situation if the servo piston (12) moves to the right (the discharge amount becomes
smaller). When LS differential pressure PLS becomes larger (for example, when the area of opening of the
control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the right.
When spool (6) moves, main port pressure PP flows from port C and port D and from port K, it enters the large
diameter end of the piston.
Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in
area between the large diameter end and the small diameter end of servo piston (12), servo piston (12) is pushed
to the right.
As a result, the swash plate moves in the direction to make angle smaller.
If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.

PC400LC-7L

10-33

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

D. When servo piston is balanced


Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the
pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as
Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS
pressure PLS are balanced, and the relationship is A0 PP = A1 Pen, servo piston (11) will stop in that
position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening
of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)
At this point, the relationship between the area receiving the pressure at both ends of piston (12) is A0: A1 = 1:2,
so the pressure applied to both ends of the piston when it is balanced becomes PP: Pen = 2:1.
The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when PP PLS = 27 kg/cm2 (384 psi). However, if PSIG (the output pressure of
0 30 kg/cm2 (426 psi) of the EPC valve of the LS valve) is applied to port G, the balance stop position will
change in proportion to pressure PSIG between PP PLS = 27 12 kg/cm2 (384 170 psi).

10-34

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

ii.

When load on actuator is large and pump discharge pressure is high


When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing spool (3) to
the right becomes larger and spool (3) moves to the position in the diagram above. When this happens, as
shown in the diagram above, part of the pressurized oil from port B flows out through port C where the LS
valve is actuated to port D, and the pressurized oil flowing from port C to the LS valve becomes
approximately half of main pump pressure PP.
When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the
large diameter end of servo piston (9), and servo piston (9) stops.
If pump discharge pressure PP and PP2 increases further and spool (3) moves further to the right, main
pump pressure PP1 flows to port C and acts to make the discharge amount the minimum. When piston (9)
moves to the right, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the
left, port C and port B are disconnected and port C and port D are interconnected. As a result, the pressure at
port C (= J) drops, and piston (9) stops moving to the right.
The position in which piston (9) stops when this happens is further to the right than the position when pump
pressures PP1 and PP2 are low.

PC400LC-7L

10-37

STRUCTURE AND FUNCTION


12

10-38

The relation of average pump pressure (PP1 + PP2)/2


and the position of servo piston (9) forms a bent line
because of the double-spacing effect of springs (4)
and (6). The relationship between average pump
pressure (PP1 + PP2)/2 and pump discharge amount
Q is shown in the figure at the right.

If command voltage X sent to PC-EPC valve solenoid


(1) increases further, the relationship between average
pump pressure (PP1 + PP2)/2, and pump discharge
amount Q is proportional to the pushing force of the
PC-EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC solenoid
(1) is added to the force pushing to the left because of
the pump pressure applied to the spool (3), so the
relationship between the average pump pressure (PP1
+ PP2)/2 and Q moves from to in accordance with the
increase in X.

HYDRAULIC SYSTEM

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

B. When pump controller is abnormal and emergency pump drive switch is ON


i.

When load on main pump is light


If there is a failure in the pump controller, turn emergency pump drive switch ON to switch to the resistor
side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is
too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (1).
When this is done, the current becomes constant, so the force pushing piston (2) is also constant.
If the main pump pressure PP1 and PP2 are low, the combined force of the pump pressure and the force of
PC-EPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the
left.
At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of
servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure
at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the
discharge amount larger.

PC400LC-7L

10-39

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

ii.

10-40

When main pump load is heavy


In the same way as in the previous item, when the emergency pump drive switch is ON, the command
current sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing
spool (3) is constant.
If main pump pressures PP1 and PP2 increase, spool (3) moves further to the right than when the main pump
load is light, and is balanced at the position in the diagram above (See Fig. P).
In this case, the pressure from port B flows to port C, so
servo piston (9) moves to the right (to make the
discharge amount smaller) by the same mechanism as
explained, and stops at a position to the right of the
position when the load on the pump is light (See Fig. Q).
In other words, even when the emergency pump drive
switch is ON, the curve for the pump pressure PP and
discharge amount Q is determined as shown in the
diagram for the valve of the current sent to the PC-EPC
valve solenoid through the resistor.
The curve when the emergency pump drive switch is ON
is curve c, which is to the left of curve b for when the
pump controller is normal.

PC400LC-7L

STRUCTURE AND FUNCTION


12
LS(PS)-EPC

HYDRAULIC SYSTEM

VALVE

1. Body

5. Coil

PSIG

: To LS(PC) valve

2. Spool

6. Plunger

PT

: To tank

3. Spring

7. Connector

PEPC

: From self-reducing pressure valve

4. Rod

PC400LC-7L

10-41

STRUCTURE AND FUNCTION

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.

When signal current is 0 (coil de-energized)


When there is no signal current flowing from the controller to
coil (5), coil (5) is de-energized.
For this reason, spool (2) is pushed to the left in the direction of
the arrow by spring (3).
As a result, port PEPC closes and the pressurized oil from the
main pump does not flow to the LS valve.
At the same time, the pressurized oil from the LS valve passes
from port PSIG(PM) through port PT and is drained to the tank.

10-42

PC400LC-7L

STRUCTURE AND FUNCTION

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.

When signal current is maximum (coil energized)


When the signal current flows to coil (5), coil (5) is energized.
When this happens, the signal current is at its maximum, so the
propulsion force of plunger (6) is also at its maximum.
For this reason, spool (2) is pushed fully to the left by push pin
(4).
As a result, the maximum flow of pressurized oil from port PEPC
flows to port PSIG(PM), and the circuit pressure between the
EPC valve and LS valve becomes the maximum.
At the same time, port PT closes and stops the oil from flowing to
the tank.

PC400LC-7L

10-43

STRUCTURE AND FUNCTION


12
VARIABLE

HYDRAULIC SYSTEM

VOLUME VALVE

1. Block

PM

: To PC valve

2. Plug

PT

: To tank

3. Spring

PEPC

: From self-reducing pressure valve

4. Piston

10-44

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Function

This stabilizes the EPC output pressure.

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

STRUCTURE AND FUNCTION


12
CONTROL

HYDRAULIC SYSTEM

VALVE

1.

6-spool valve

2.

Cover 1

3.

Cover 2

4.

Pump merge-divider valve

5.

Back pressure valve

6.

Boom lock valve

7.

Boom, arm Hi valve

8.

Quick return valve

9.

Boom Hi check valve

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

: To bucket cylinder bottom

P11

: From arm PPC valve

A2

: o left travel motor

P12

: From arm PPC valve

A3

: To boom cylinder bottom

BP1

: Boom RAISE PPC output pressure

A4

: To swing motor

PB5

: From 2-stage safety valve solenoid valve

A5

: To right travel motor

PLS1

: To rear pump control

A6

: To arm cylinder head

PLS2

: To front pump control

A-1

: To boom cylinder bottom

PP1

: To rear pump control

A-2

: To attachment

PP2

: To front pump control

B1

: To bucket cylinder head

PPS1

: From rear main pump

B3

: To bottom cylinder head

PPS2

: From front main pump

B4

: To swing motor

PR

: To solenoid valve, PPC valve, EPC valve

B5

: To right travel motor

PS

: From pump merge-divider solenoid valve

B6

: To arm cylinder bottom

PST

: From travel junction valve

B-1

: To arm cylinder bottom

PX1

: From 2-stage solenoid valve

P1

: From bucket PPC valve

PX2

: From 2-stage solenoid valve

P2

: From bucket PPC valve

SA

: Pressure sensor fitting port

P3

: From left travel PPC valve

SB

: Pressure sensor fitting port

P4

: From left travel PPC valve

: To tank

P5

: From boom PPC valve

T1

: To tank

P6

: From boom PPC valve

TS

: To tank

P7

: From swing PPC valve

TSW

: To swing motor

P8

: From swing PPC valve

P9

: From right travel PPC valve

P10

: From right travel PPC valve

10-46

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
7-SPOOL VALVE
(1/9)

PC400LC-7L

10-47

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(3/9)

1. Unload valve

9. Pressure compensation valve (Arm IN)

2. Pressure compensation valve (Arm OUT)

10. Pressure compensation valve (Bucket DUMP)

3. Pressure compensation valve (Right travel reverse

11. Pressure compensation valve (Left travel forward)

4. Pressure compensation valve (Left swing)

12. Pressure compensation valve (Boom LOWER)

5. Pressure compensation valve (Boom RAISE)

13. Pressure compensation valve (Right swing)

6. Pressure compensation valve (Left travel reverse)

14. Pressure compensation valve (Right travel forward

7. Pressure compensation valve (Bucket CURL)

15. Pressure compensation valve (Arm IN)

8. Pressure compensation valve (Boom RAISE)

16. Main relief valve

PC400LC-7L

10-49

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(4/9)

1. Spool (Arm)

6. Spool (Bucket)

2. Spool (Right travel)

7. Spool (Boom Hi)

3. Spool (Swing)

8. Spool (Arm Hi)

4. Spool (Boom)

9. Unload valve

5. Spool (Left travel)

10. Main relief valve

Unit: mm
No.

11

Criteria

Check item

Spool return spring

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

Spool return spring

54.6 x 34.8

51.2

429.9 N
{42.9 kg}

---

336.1 N
{34.3 kg}

13

Spool return spring

54.5 x 34.8

51.2

393 N
{40.1 kg}

---

314.6 N
{32.1 kg}

14

Spool return spring

54.9 x 24.2

51.2

251 N
{25.1 kg}

---

201.0 N
{20.5 kg}

15

Spool return spring

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(5/9)

1. Safety-suction valve (Arm OUT)

9. Safety-suction valve (2-stage) (Boom LOWER)

2. Suction valve (Right travel reverse)

10. Suction valve (Right travel forward)

3. Suction valve (Boom RAISE)

11. Safety-suction valve (Arm IN)

4. Suction valve (Left travel reverse)

12. LS shuttle valve (Arm, right travel)

5. Safety-suction valve (Boom Hi)

13. LS select valve

6. Safety-suction valve (Arm IN)

14. LS shuttle valve (Boom, left travel, bucket)

7. Safety-suction valve (Bucket DUMP)

15. LS check valve

8. Suction valve (Left travel forward)

16. Pressure relief plug

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
17

Check valve spring

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(6/9)

ARM CONTROL VALVE

R. H. TRAVEL CONTROL VALVE

1. Unload valve

5. Safety-suction valve

12. Suction valve

2. Main relief valve

6. Spool

13. Spool

3. Safety valve (Boom RAISE)

7. Pressure compensation valve (OUT)

14. Pressure compensation valve (Reverse)

4. Lift check valve

8. LS shuttle valve

15. LS shuttle valve

9. Pressure compensation valve (IN)

16. Pressure compensation valve (Forward)

10. Safety-suction valve

17. Suction valve

11. Check valve for regeneration circuit

10-52

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria

Remedy

Standard size
Free length x OD Installed length
18

Regeneration valve spring

19
20

Repair limit
Installed load

Free length Installed load

31.5 x 10.3

19.5

6.2 N
{0.6 kg}

---

4.9 N
{0.5 kg}

Piston return spring

36.9 x 11.1

28

29.4 N
{3 kg}

---

23.5 N
{2.4 kg}

Piston return spring

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(7/9)

SWING CONTROL VALVE

ARM CONTROL VALVE

L. H. TRAVEL CONTROL VALVE

1. Spool

5. Suction valve

13. Pump merge-divider valve (Travel junction valve)

2. Pressure compensation valve (Left)

6. Spool

14. Return spring

3. LS select valve

7. Pressure compensation valve (RAISE)

15. Suction valve

4. Pressure compensation valve (Right)

8. Hydraulic drift prevention valve

16. Spool

9. LS shuttle valve

17. Pressure compensation valve (Reverse)

10. Pressure compensation valve (Lower)

18. LS shuttle valve

11. Safety-suction valve

19. Pressure compensation valve (Forward)

12. Check valve for regeneration circuit

20. Suction valve

10-54

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria

Remedy

Standard size
21

Regeneration valve spring

Free length x OD Installed length

Repair limit
Installed load

Free length Installed load

31.5 x 10.3

19.5

6.2 N
{0.6 kg}

---

4.9 N
{0.5 kg}

22

Piston return spring

48.1 x 10.8

28

17.5 N
{1.8 kg}

---

14.0 N
{1.4 kg}

23

Piston return spring

36.9 x 11.1

28

29.4 N
{3 kg}

---

23.5 N
{2.4 kg}

24

Spool return spring

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(8/9)

BUCKET CONTROL VALVE

BOOM, ARM HI VALVE

1. Safety-suction valve

7. Boom Hi spool

2. Spool

8. Pressure compensation valve (Boom RAISE)

3. Pressure compensation valve (CURL)

9. Boom Hi check valve

4. LS shuttle valve

10. Quick-return valve

5. Pressure compensation valve (DUMP)

11. Pressure compensation valve (Arm IN)

6. Safety-suction valve

12. Arm Hi spool


13. Safety-suction valve

10-56

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria

Remedy

Standard size
14

15

Piston return spring

Piston return spring

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
(9/9)

1. Unload valve

9. LS bypass plug

2. Main relief valve

10. Screw

3. Pump merge-divider valve (Main)

11. Poppet

4. Return spring

12. Spring (Pressure reducing valve pilot)

5. Pump merge-divider valve (For LS)

13. Spring (Pressure reducing valve main)

6. Return spring

14. Valve (Pressure reducing valve)

7. Valve (Sequence valve)

15. Spring (Safety valve)

8. Spring (Sequence valve)

16. Ball

10-58

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria

Remedy

Standard size
17

Check valve spring

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

Spool return spring

46.6 x 21.8

3.3

156.8 N
{16.0 kg}

125.5 N
{12.8 kg}

19

Spool return spring

64.5 x 32.3

63

177.5 N
{18.1 kg}

142.0 N
{14.5 kg}

20

Sequence valve spring

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

STRUCTURE AND FUNCTION


12
MAIN

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.

When pilot pressure P is OFF: Low-pressure setting.


The set pressure is determined by the installed load of spring (1).

2.

When pilot pressure P is ON: High-pressure setting.


In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter (d1) so the set pressure
becomes higher.

10-60

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

MEMORANDUM

PC400LC-7L

10-61

STRUCTURE AND FUNCTION


12
CLSS

HYDRAULIC SYSTEM

(CLOSED CENTER LOAD SENSING 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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Basic principle
1.

Control of pump swash plate


The pump swash plate angle (pump discharge amount) is
controlled so that LS differential pressure PLS (the
difference between pump pressure PP and control valve
outlet port LS pressure PLS) (load pressure of actuator) is
constant.
(LS pressure PLS = Pump discharge pressure PP LS
pressure PLS)

If LS differential pressure PLS becomes lower than the set


pressure of the LS valve (when the actuator load pressure is
high), the pump swash plate moves towards the maximum
position; if it becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low), the pump swash
plate moves towards the minimum position.

PC400LC-7L

10-63

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
SELF

HYDRAULIC SYSTEM

PRESSURE REDUCING VALVE

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.

When engine is stopped.


Poppet (11) is pressed by spring (12) against the seat and port
PR is not connected to TS.
Valve (14) is pressed by spring (13) against the left side and port
P2 is connected to PR.
Valve (7) is pressed by spring (8) against the left side and port
P2 is not connected to A2.

PC400LC-7L

10-65

STRUCTURE AND FUNCTION

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.

When load pressure P2 is high


If load pressure A2 rises and the pump discharge increases
because of operation of the work equipment, the fdx P2 pressure
rises higher than the total of the force of spring (8) and the value
of d PR pressure, and then valve (7) moves to the right stroke
end.
As a result, the area of the pass between ports P2 and A2
increases and the pass resistance lowers and the loss of the
engine power is reduced.
If the PR pressure rises above the set pressure, poppet (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.

10-66

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
SWING

HYDRAULIC SYSTEM

MOTOR

KMF230ABE-5

: From swing lock solenoid valve

: From control valve

: To tank

MA

: From control valve

MB

: From control valve

10-68

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

Specifications
Model

KMF230ABE-5

Theoretical displacement

229.4 cm3/rev
2
285+0.5
0 kg/cm

Safety valve set


pressure

(396.8 +7.1
0 psi)

Rated revolving
speed

1,413 rpm

Brake release
pressure

19 4 kg/cm2 (270.2 56.8 psi)

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

1. Brake spring

8. Housing

15. Safety valve

2. Drive shaft

9. Piston

16. Check valve

3. Spacer

10. Cylinder block

17. Shuttle valve

4. Case

11. Valve plate

5. Disc

12. Reverse prevention valve

6. Plate

13. Center shaft

7. Brake piston

14. Center spring

10-70

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria

Remedy

Standard size
18

19

Check valve spring

Shuttle valve spring

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

STRUCTURE AND FUNCTION


12
RELIEF

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
C. Operation of swing lock
i.

When swing lock solenoid valve is deactivated


When the swing lock solenoid valve is deactivated, the
pressurized oil from the main pump is shut off and port B is
connected to the tank circuit.
As a result, brake piston (7) is pushed down by brake spring
(1), discs (5) and plates (6) are pushed together, and the
brake is applied.

ii.

When swing lock solenoid valve is activated


When the swing lock solenoid valve is activated, the valve
is switched and the pressure oil from the main pump enters
port B and flows to brake chamber a.
The pressure oil entering chamber a overcomes brake spring
(1) and pushes brake piston (7) up. As a result, discs (5) and
plates (6) are separated and the brake is released.

PC400LC-7L

10-73

STRUCTURE AND FUNCTION


12
REVERSAL

HYDRAULIC SYSTEM

PREVENTION VALVE

Outline diagram

Explanation of effect

10-74

PC400LC-7L

STRUCTURE AND FUNCTION

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.

When brake pressure is being generated at port MB


Pressure MB passes through the notch and goes to chamber d, spool
(5) pushes spring (6) according to the difference in area D1 > D2,
moves to the left, and MB is connected to e.
When this happens, pressure MA is below the set pressure of spring
(3), so spool (2) does not move. For this reason, the pressure oil is
closed by spool (2), and the braking force is ensured.

2.

After motor stops


The motor is reversed by the closing pressure generated at port
MB. (1st reversal)
When this happens, reversal pressure is generated at port MA.
Pressure MA goes to chamber a, so spool (2) pushes spring (3)
and moves to the right, and MA is connected to B. At the same
time, b is connected to f through the drill hole in spool (5), so the
reversal pressure at port MA is bypassed to port T to prevent the
2nd reversal.

PC400LC-7L

10-75

STRUCTURE AND FUNCTION


12
CENTER

HYDRAULIC SYSTEM

SWIVEL JOINT

1. Cover

A1

: To LH travel motor port PB

T2

: To tank

2. Body

A2

: From control valve port A2

T1

: From LH and RH travel motors port T

3. Slipper seal

C1

: To RH travel motor port PA

D2

: From control valve port B5

4. O-ring

B2

: From control valve port B2

B1

: To LH travel motor port PA

5. Shaft

D1

: To RH travel motor port PB

C2

: From control valve port A5

: To LH and RH travel motors port P

Unit: mm
No.
6

Check item
Clearance between rotor and shaft

10-76

Criteria

Remedy

Standard Size

Standard clearance

Repair limit

80

---

---

If damaged or deformed, replace


spring

PC400LC-7L

STRUCTURE AND FUNCTION


12
TRAVEL

HYDRAULIC SYSTEM

MOTOR

KMV280ADT

Port T (to tank)


Port PA (from control valve)
Port PB (from control valve)
Port PI (from travel speed solenoid valve)

Item

Specifications
Model:
Theoretical delivery

KMV200ADT
Min 130 cm3/rpm
Max 200 cm3/rpm

Brake releasing pressure:

10 4 kg/cm2 (142.2 56.8 psi)

Travel speed switching pressure:

8 +4 kg/cm2 (113.7 +56.8


-14.2 psi)
(Differentical pressure)

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

1. Output shaft

8. Regulator piston

15. Safety valve

2. Motor case

9. Plate

16. Rgegulator valve

3. Piston

10. Disc

17. Spring

4. Cylinder

11. Check valve spring

18. Brake spring

5. Valve plate

12. Check valve

19. Brake piston

6. End cover

13. Counterbalance valve

20. Check valve

7. Slow return valve

14. Spool return spring

10-78

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12
Unit: mm
No.

Check item

Criteria
Standard size

21

Spool return spring

22

Check valve spring

23

Regulator piston spring

Freelength x OD

Remedy
Repair limit

Installed length Installed load Free length

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
PARKING
1.

HYDRAULIC SYSTEM

BRAKE

When starting to travel

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

Operation when pressurized oil is supplied


When the travel lever is operated, the pressurized oil from
the control valve is supplied to port PA. It pushes open
check valve (12a) and flows from motor inlet port MA to
motor outlet port MB. However, the motor outlet port is
closed by check valve (12b) and spool (13), so the pressure
at the supply side rises.

PC400LC-7L

STRUCTURE AND FUNCTION


12

HYDRAULIC SYSTEM

The pressurized oil at the supply side flows from orifice E1


in spool (13) and orifice E2 in the piston to chamber S1.
When the pressure in chamber S1 goes above the spool
switching pressure, spool (13) is pushed to the right. As a
result, port MB and port PB are connected, the outlet port
side of the motor is opened, and the motor starts to rotate.

ii.

Operation of brake when traveling downhill


If the machine tries to run away when traveling downhill,
the motor will turn under no load, so the pressure at the
motor inlet port will drop, and the pressure in chamber S1
through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops below the spool
switching pressure, spool (13) is returned to the left by
spring (14), and outlet port MB is throttled.
As a result, the pressure at the outlet port side rises,
resistance is generated to the rotation of the motor, and this
prevents the machine from running away.
In other words, the spool moves to a position where the
pressure at outlet port MB balances the pressure at the inlet
port and the force generated by the weight of the machine. It
throttles the outlet port circuit and controls the travel speed
according to the amount of oil discharged from the pump.

B. Safety valve (2-direction operation, 2-stage set safety valve)


Function
When travel is stopped (or when traveling downhill), the circuits
at the inlet and outlet ports of the motor are closed by the
counterbalance valve. However, the motor is rotated by inertia,
so the pressure at the outlet port of the motor will become abnormally high and will damage the motor or piping.
The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent
damage to the equipment.

PC400LC-7L

10-85

STRUCTURE AND FUNCTION


12

HYDRAULIC SYSTEM

Operation in both directions


i.

When pressure in chamber MB has become high (when


rotating clockwise)
When the travel is stopped (or when traveling downhill),
chamber MB 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.
If the pressure goes above the set pressure, the force
produced by the difference in area between D1 and D2
[x/4 (D12 D2) pressure] overcomes the force of the
spring and moves the poppet to the left, so the oil flows to
chamber MA in the circuit on the opposite side.

ii.

When stopping travel (low-pressure setting)


When the travel lever is placed at neutral, the pressure in
chamber PA drops and counterbalance valve spool (13)
returns to the neutral position. While the counterbalance
valve spool (13) is returning to the neutral position, the
pressurized oil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. The piston moves
to the left, and the set load becomes smaller.
Because of this, the set pressure of the safety valve is
switched to the low-pressure setting and relieves the shock
when reducing speed.

[Set pressure of safety valve]


When starting or traveling:
High-pressure setting
410 kg/cm2 (0.583 psi)

10-86

When stopping:
Low-pressure setting
27.5 kg/cm2 (0.0391 psi)

PC400LC-7L

STRUCTURE AND FUNCTION

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.

If the pressure goes above the set pressure, the force


produced by the difference in area between D1 and D3
[x/4 (D32 D12) pressure] overcomes the force of the
spring and moves the poppet to the left, so the oil flows to
chamber MB in the circuit on the opposite side.

Operation of mechanism for varying set pressure


A. When starting travel (high-pressure setting)
When the travel lever is operated, the pressurized oil from the
pump actuates counterbalance valve spool (19), and opens the
pilot circuit to the safety valve. The oil passes from chamber G
to passage H and flows into chamber J, pushes the piston to the
right, and compresses the spring to make the set load larger.
Because of this, the set pressure of the safety valve is switched to
the high pressure setting, and a large draw bar pull is made available.

PC400LC-7L

10-87

STRUCTURE AND FUNCTION


12
TRAVEL

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
CONTROL

HYDRAULIC SYSTEM

VALVE

Lever positions
1. Travel PPC valve

8. Solenoid valve

(1) Hold

(9) Swing RIGHT

2. Service PPC valve

9. Accumulator

(2) Boom RAISE

(10) Swing LEFT

3. Service pedal

10. Control valve

(3) Boom LOWER

(11) Neutral

4. L.H. travel lever

11. Hydraulic pump

(4) Bucket DUMP

(12) Travel REVERSE

5. R.H. travel lever

12. Junction box

(5) Bucket CURL

(13) Travel FORWARD

6. R.H. PPC valve

13. L.H. work equipment control lever

(6) Hold

7. R.H. work equipment control lever

14. L.H. PPC valve

(7) Arm IN
(8) Arm OUT

10-90

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

MEMORANDUM

PC400LC-7L

10-91

STRUCTURE AND FUNCTION


12
TRAVEL

HYDRAULIC SYSTEM

PPC SHUTTLE VALVE

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.

When travel is at neutral


Stroke limit signal chambers a and b are connected to the travel PPC valve through orifices (5) and (6) in pistons (3)
and (4) inside the travel spring case, and the is drained.
When arm IN is operated, spool (1) moves to the right by stroke (st0) to a point where it contacts the end face of
spring case (2).
When boom RAISE is operated, spool (9) moves to the left by stroke (st3) to a point where it contacts the end face of
spring case (10).

10-92

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

PC400LC-7L

10-93

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

WORK EQUIPMENT SWING PPC VALVE

: From self pressure reducing valve

P1

:Left PPC: Arm OUT / Right PPC: Boom LOWER

: To tank

P2

:Left PPC: Arm IN / Right PPC: Boom RAISE

P3

:Left PPC: Swing LEFT / Right PPC: Bucket CURL

P4

:Left PPC: Swing RIGHT / Right PPC: Boom LOWER

PC400LC-7L

10-95

STRUCTURE AND FUNCTION

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

6. Nut (For connection of lever)

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
12

Centering spring
(For P3 and P4)

Free length x OD Installed length

Repair limit
Installed load

Free length

42.4 x 15.5

34

17.1 N {1.8 kg}

---

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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.

During fine control (neutral fine control)


When piston (4) starts to be pushed by disc (5), retainer (9) is pushed;
spool (1) is also pushed by metering spring (2), and moves down.
When this happens, fine control hole f is shut off from drain chamber
D, and at almost the same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the main pump passes through
fine control hole f and goes from port P1 to port A.
When the pressure at port P1 becomes higher, spool (1) is pushed
back and fine control hole f is shut off from pump pressure chamber
PP. At almost the same time, it is connected to drain chamber D to
release the pressure at port P1.
When this happens, spool (1) moves up or down so that force of
metering spring (2) is balanced with the pressure at port P1. The
relationship in the position of spool (1) and body (10) (fine control
hole f is at a point midway between drain hole D and pump pressure
chamber PP) does not change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed proportionally to the
amount of movement of the control lever, so the pressure at port P1
also rises in proportion to the travel of the control lever. In this way,
the control valve spool moves to position where the pressure in
chamber A (the same as the pressure at port P1) and the force of the
control valve spool return spring are balanced.

10-98

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
TRAVEL

10-100

HYDRAULIC SYSTEM

PPC VALVE

: From self pressure reducing valve

P3 : Right reverse

: To tank

P4 : Right forward

P1

: Left reverse

P5 : Travel signal

P2

: Left forward

P6 : Steering signal

PC400LC-7L

STRUCTURE AND FUNCTION

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. Steering signal valve spring

10-101

STRUCTURE AND FUNCTION

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}

Steering signal spring

12.8 x 7.3

8.5

8.8 N
{0.9 kg}

10-102

Remedy

Free length x OD

Free length Installed load


If damaged or
deformed, replace
spring

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
SERVICE

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

Free length x OD Installed length

Repair limit
Installed load

Free length 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

STRUCTURE AND FUNCTION


12
SOLENOID

HYDRAULIC SYSTEM

VALVE

PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid valves.

1. PPC lock solenoid valve

2. Travel junction solenoid valve

A1 : To No. 1 pump (CO valve)

3. Merge-divider solenoid valve

A2 : To main valve (Travel junction valve) ACC : To accumulator

4. Travel speed solenoid valve

A3 : To main valve (Merge-divider valve)

5. Swing brake solenoid valve

A4 : To both travel motors

6. Machine push-up solenoid valve

A5 : To swing motor

8. 2-stage relief solenoid valve

A6 : To 2-stage safety valve at boom


cylinder head

PC400LC-7L

: To tank

A8

: To main valve (2-stage relief valve)

P1

: From main pump

10-109

STRUCTURE AND FUNCTION

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.

WHEN SOLENOID IS TURNED ON

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

STRUCTURE AND FUNCTION


12
PPC

HYDRAULIC SYSTEM

ACCUMULATOR

PC400LC-7L

10-111

STRUCTURE AND FUNCTION


12
RETURN

HYDRAULIC SYSTEM

OIL FILTER

FOR BREAKER

Specifications

10-112

1. Drain plug

Rated pressure

: 70 kg/cm2 (995.6 psi)

2. Element

Flow

: 200 L/min (52.8 gal)

3. Case

Relief valve cracking pressure:

3.5 0.5 kg/cm2 (49.7 7.1 psi)

4. Head cover

Filter mesh size

: 6 m

5. Relief valve

Filtering area

: 4,570 cm2 (708 in 2)

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

MEMORANDUM

PC400LC-7L

10-113

STRUCTURE AND FUNCTION


12
BOOM

HYDRAULIC SYSTEM

HYDRAULIC DRIFT PREVENTION VALVE

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

PC400LC-7L

10-115

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

PC400LC-7L

10-117

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

ARM HYDRAULIC DRIFT PREVENTION VALVE


(If equipped)
Function

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
QUICK

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
LIFT

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.

While engine is stopped


Any oil is not supplied from the pump to the self pressure reducing
valve and valve (1) is pressed by only the force of spring (2) toward
the right and drain circuit a of the control valve is connected
through orifice b of valve (1) to port T.

2.

While engine is running


Output pressure PR of the self pressure reducing valve is applied
through the control valve to spring chamber c of the back
pressure valve.
Output pressure PR applied to spring chamber c is applied to
the left end of valve (1) (area of d) to push valve (1) to the right.
At this time, pressure PA of drain circuit a of the control valve
is applied to the right end of valve (1) (area of d1) to push valve
(1) to the left.
Valve (1) is balanced so that the back pressure PA will be as
follows.
PA = {(Area of d) PR + Force of spring (2)} / (Area of d1)

PC400LC-7L

10-125

STRUCTURE AND FUNCTION


12
ATTACHMENT

HYDRAULIC SYSTEM

CIRCUIT SELECTOR VALVE

1. Spool

:To control valve

2. Spring

:To hydraulic tank

ATT

:To attachment

ACC

:To accumulator

P1

:From attachment circuit selector solenoid valve

TS

:To hydraulic tank

Unit: mm
No.

Check item

Criteria
Standard size

Spool return spring

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

STRUCTURE AND FUNCTION

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.

When attachment other than breaker is installed


Spool (1) is pushed fully to the left by the force of spring (2), ATT
port and port V are interconnected, and ATT port and port T are shut
off, so the attachment and main valve are interconnected.

2.

When breaker is installed


When the pilot pressure from the attachment circuit selector solenoid
valve overcomes the force of spring (2), the spool (1) moves fully to
the right. ATT port and port V are shut off and ATT port and port T
are interconnected, so the oil returning from the breaker does not
pass through the main valve, but passes through port T and returns
directly to the hydraulic tank.

PC400LC-7L

10-127

STRUCTURE AND FUNCTION


12
HOLDING

HYDRAULIC SYSTEM

VALVE

Downward movement prevention valve (For boom and arm)

1.

10-128

Bolt

:From control valve

:To hydraulic tank

CY

:To hydraulic cylinder

PI

:From PPC valve

PCY

:Fror pressure pickup and equalizer circuits

Torque Nm

Torque lbf ft

30.9 3.4

22.7 2.5

PC400LC-7L

STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM

12

1. Pilot spool

4. Safety valve

2. Spring (1st stage of spool)

5. Check valve

3. Spring (2nd stage of spool)

6. Spring

Unit: mm
No.

Check item

Criteria

Remedy

Standard size
7

Check valve spring

Free length x OD Installed length

Repair limit
Installed load

20.8 x 12.2

13.5

12.7 N
{1.3 kg}

Free length Installed load


---

9.8 N
{1.0 kg}

Spool return spring

41.1 x 9.6

35

58.8 N
{6.0 kg}

---

47.0 N
{4.8 kg}

Spool return spring

41.9 x 25.8

41

78.4 N
{8.0 kg}

---

62.7 N
{6.4 kg}

10

Spool return spring

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

STRUCTURE AND FUNCTION

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.

When the work equipment is in neutral


[When piping is normal]
Check valve (5) is closed by the work equipment cylinder
holding pressure applied through port CY to chamber b.
When the work equipment is in neutral, no pilot pressure is
applied from the PPC valve to port Pi. Accordingly, pilot spool
(1) is moved to the left end by the force of springs (2) and (3),
then chambers a and b are shut of from each other.
By this operation, oil does not flow between the main valve and
the work equipment cylinder, thus the work equipment cylinder
held.
If the pressure in the work equipment cylinder rises abnormally
high, work equipment cylinder holding pressure Pb operates
safety valve (4).
In the downward movement prevention valves for the boom,
chambers b of both of them are connected through ports PCY.
Accordingly, even if the leakages are different between both
valves, the pressures in both chambers b become the same.
[When piping bursts]
Even if piping A between the main valve and work equipment
cylinder bursts, chamber a is shut off from chamber b as in
the case where the piping is normal. Accordingly, the work
equipment cylinder is held.

2.

When oil is sent from main valve to cylinder


[When piping is normal]
If pressure Pa of the oil sent from the main valve to chamber a
is higher than the total of pressure Pb in chamber b connected
to the work equipment cylinder and the force of spring (6), check
valve (5) opens and chambers and the oil flows from the main
valve to the work equipment cylinder.

[When piping bursts]


If piping A between the main valve and the work equipment
cylinder bursts, the oil in chamber a flows out through the
burst part and pressure Pa in chamber a lowers.
If Pa lowers below the total of pressure Pb in chamber b and
the force of spring (6), check valve (5) closes and chambers a
and b are shut off from each other. Accordingly, pressure Pb
in the cylinder is held and the work equipment does not fall
suddenly.

10-130

PC400LC-7L

STRUCTURE AND FUNCTION

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.

[When piping bursts]


If piping A between the main valve and work equipment
cylinder bursts, the oil in chamber a flows out through the
burst part. Since the oil supplied from chamber b to chamber
a flows through opening c of spool (1), however, the
cylinder does not fall suddenly.

PC400LC-7L

10-131

STRUCTURE AND FUNCTION


12
HYDRAULIC

HYDRAULIC SYSTEM

CYLINDER

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-132

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

WORK EQUIPMENT

12

WORK EQUIPMENT

10-134

PC400LC-7L

STRUCTURE AND FUNCTION

WORK EQUIPMENT

12
Unit: mm
No.

Check item

Criteria

Clearance between connecting pin


Standard size
and bushing of revolving frame
and boom

Tolerance

Remedy

Shaft

Hole

Standard
clearance

Clearance
limit

120

-0.036
-0.090

+0.173
+0.101

0.137 0.263

1.0

Clearance between connecting pin


and bushing of boom and arm

120

-0.036
-0.090

+0.180
+0.112

0.148 0.270

1.0

Clearance between connecting pin


and bushing of arm and link

100

-0.036
-0.090

+0.172
+0.081

0.117 0.262

1.0

Clearance between connecting pin


and bushing of arm and bucket

100

-0.036
-0.090

+0.138
+0.077

0.113 0.228

1.0

Clearance between connecting pin


and bushing of link and bucket

100

-0.036
-0.090

+0.172
+0.081

0.117 0.262

1.0

Clearance between connecting pin


and bushing of link and link

100

-0.036
-0.090

+0.190
+0.097

0.133 0.280

1.0

Bucket clearance (a)

0.5 - 1.0

Bucket clearance (b)

2.0

PC400LC-7L

Replace

Adjust shims

10-135

STRUCTURE AND FUNCTION


12
DIMENSION

10-136

WORK EQUIPMENT

ARM

PC400LC-7L

STRUCTURE AND FUNCTION

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

371+10 / 370 0.5


-0.036
100+0.1
0 / -0.090
0
355-0.5

370

Cylinder Min. stroke

1,870

Cylinder Max. stroke

3,140

PC400LC-7L

10-137 2

STRUCTURE AND FUNCTION


12
DIMENSION

10-138

WORK EQUIPMENT

OF BUCKET

PC400LC-7L

STRUCTURE AND FUNCTION


12

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

STRUCTURE AND FUNCTION

AIR CONDITIONER

12

AIR CONDITIONER
AIR CONDITIONER PIPING

1. Hot water pickup piping

A. Fresh air

2. Receiver tank

B. Recirculated air

3. Hot water return piping

C. Hot air/cold air

4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct

10-140

PC400LC-7L

STRUCTURE AND FUNCTION

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.

ENGINE SPEED CONTROL


The fuel control dial sends signal voltages to the engine controller
according to its angle.
The engine controller sends drive signals to the supply pump according to
the signal voltages received from the fuel control dial and controls the fuel
injection pump to control the engine speed.

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

STRUCTURE AND FUNCTION


12
COMPONENTS

ENGINE CONTROL

OF SYSTEM

FUEL CONTROL DIAL

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

STRUCTURE AND FUNCTION


12
ENGINE

ENGINE CONTROL

CONTROLLER

PC400LC-7L

10-143

STRUCTURE AND FUNCTION

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

POWER (+24V constant)

CN2-1

GND

CN1-2

POWER (+24V constant)

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

Sensor 5V power supply 2

CN1-10

GND

CN2-10

Fuel control dial

Input

Input

Output
Input

CN1-11

NC

Input

CN2-11

S_NET_SHIELD GND

CN1-12

NC

Output

CN2-12

CAN_SHIELD

CN1-13

Key switch (ACC)

Input

CN2-13

NC

Output

CN1-14

NC

Input

CN2-14

RS232C_1TX

Output

CN1-15

Engine oil pressure switch


(For high pressure)

Input

CN2-15

G_SHIELD (GND)

CN1-16

Memory clear

Input

CN2-16

Ne_SHIELD (GND)

CN1-17

Model selection 3

Input

CN2-17

Fuel temperature sensor

Input

CN1-18

NC

Output

CN2-18

NC

Input

CN1-19

Key switch (ACC)

Input

CN2-19

Sensor 5V power supply 1

CN1-20

Starting switch (C)

Input

CN2-20

Boost pressure sensor

CN1-21

Engine oil pressure switch


(For low pressure)

Input

CN2-21

S_NET (+)

Input/Output

CN1-22

Auto deceleration signal

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

Coolant temperature sensor (High)

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

Coolant temperature sensor (Low)

Input

CN2-38

NC

Input

CN2-39

Analog GND

CN2-40

Common rail pressure sensor

10-144

Output
Input

Input

Input

PC400LC-7L

STRUCTURE AND FUNCTION

ENGINE CONTROL

12
CN3 [CN-E13]
Pin No.

Signal name

Input/Output

CN3-1

Power supply for power

CN3-2

Power supply for power

CN3-3

NC

CN3-4

NC

CN3-5

Injector #3 (+)

Output

CN3-6

Injector #2 (+)

Output

CN3-7

NC

Input

CN3-8

Output mode selection 1 (Test mode)

Input

CN3-9

Lever neutral flag (Test mode)

Input

CN3-10

Engine rotation pulse output

Output

CN3-11

Power GND

CN3-12

Supply pump 1 (+)

Output

CN3-13

Supply pump 2 (+)

Output

CN3-14

Injector #1 (+)

Output

CN3-15

Injector #3 ()

Output

CN3-16

Injector #2 ()

Output

CN3-17

NC

Input

CN3-18

Output mode selection 2 (Test mode)

Input

CN3-19

NC

CN3-20

Q command output

CN3-21

Power supply for power

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

Auto deceleration flag (Test mode)

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

Auto deceleration control (Test mode)

Input

CN3-39

NC

Input

CN3-40

GND

PC400LC-7L

Input

Input
Output

10-145

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12

ELECTRONIC CONTROL SYSTEM


CONTROL FUNCTIONS

For the self-diagnosis function, see TROUBLE SHOOTING

10-146

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12

MEMORANDUM

PC400LC-7L

10-147

STRUCTURE AND FUNCTION


12
TOTAL

10-148

ELECTRONIC CONTROL SYSTEM

SYSTEM DIAGRAM

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12

PC400LC-7L

10-149

STRUCTURE AND FUNCTION


12
ENGINE

10-150

ELECTRONIC CONTROL SYSTEM

AND PUMP CONTROL FUNCTION

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12
1. Control method in each mode Mode A, Mode E
Matching point in mode A: Rated speed

Mode A

246.3 kW/1,850 rpm


{331 HP/1,850 rpm}

Mode E

213.3. kW/1,720 rpm


{286 HP/1,720 rpm}

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12
Mode B / (Mode L)
Mode

Mode B

Mode

Partial output point

82%

61%

Mode B

194.9 kW/1,730 rpm


{261 HP / 1,730 rpm}

Mode L

150.8 kW/1,250 rpm


{202 HP / 1,250 rpm}

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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.

If the machine travels in mode L, the working mode and engine


speed do not change, but the pump absorption torque is
increased.
: The L mode is on the multi-monitor specification machine only.

3.

Function to control when emergency pump drive switch is turned ON


Even if the controller or a sensor has a trouble, the functions of
the machine can be secured with pump absorption torque almost
equivalent to mode E by turning on emergency pump drive
switch (10).
In this case, a constant current flows from the battery to the EPC
valve for PC and the oil pressure is sensed by only the EPC
valve for PC.

10-154

PC400LC-7L

STRUCTURE AND FUNCTION


12
PUMP/VALVE

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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.

2-stage relief function


The relief pressure in the normal work is 355 kg/cm2 (5049 psi).
If the 2-stage relief function is turned on, however, the relief
pressure rises to about 380 kg/cm2 (5404 psi).
By this operation, the hydraulic force is increased further.
Operating condition for turning on 2-stage relief function
Condition

Relief pressure

Condition
During travel
When swing lock switch is turned on
355 kg/cm2 (5049 psi)

When boom is lowered


2
When one-touch power maximizing function is 380 kg/cm (5404 psi)
turned on
When L mode is operated

: The L mode is on the multi-monitor specification machine only.

10-156

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12

MEMORANDUM

PC400LC-7L

10-157

STRUCTURE AND FUNCTION


12
ONE-TOUCH

ELECTRONIC CONTROL SYSTEM

POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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

2-stage relief function

Operation time

Software cut-off function

355 kg/cm (5049 psi)

380 kg/cm2 (5404 psi)

Automatically reset at 8.5


sec

Cancel

A, E

2.

Matching at rated output point

Machine push-up function


Operate switch (1) to increase the boom pushing force when
digging ditches or holes on hard ground.

Switch

2-stage safety valve function

OFF

Setting of safety valve at boom cylinder


150 kg/cm2 (2133 psi)

ON

Setting of safety valve at boom cylinder


290 kg/cm2 (4124 psi)

PC400LC-7L

10-159

STRUCTURE AND FUNCTION


12
AUTO-DECELERATION

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION


12
AUTO-WARM-UP/OVERHEAT

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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.

Overheat prevention function


If the engine coolant temperature rises too high during work, the pump load and engine speed are reduced to prevent
overheating.
This function is turned on when the coolant temperature rises above 95 C (203 F).

PC400LC-7L

10-163

STRUCTURE AND FUNCTION


12
SWING

ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTION

Function
The swing lock and swing holding brake functions are installed.

10-164

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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

Swing holding brake

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.

: Operation of swing holding brake release switch

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.

Swing holding brake release switch

ON
(When control has trouble)

OFF
(When controller is normal)

Swing lock switch

ON

OFF

ON

OFF

Swing brake

Swing lock is turned


on

Swing lock is
canceled

Swing lock is
turned on

Swing holding brake 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.

Quick hydraulic oil warm-up function when swing lock switch is


turned on
If swing lock switch (4) is turned on, the pump-cut function is
cancelled and the relief pressure rises from 355 kg/cm2 (5049 psi) to
380 kg/cm2 (5404 psi). If the work equipment is relieved under this
condition, the hydraulic oil temperature rises quickly and the warm-up
time can be shortened.

PC400LC-7L

10-165

STRUCTURE AND FUNCTION


12
TRAVEL

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

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.

Travel speed change function


A. Manual change with travel speed switch If the travel speed switch is changed between Lo, (Mi), and Hi, the
governor/pump controller controls the pump capacity and motor capacity at each gear speed as shown at right to
change the travel speed.
Travel speed switch
Pump capacity (%)
Motor capacity
Travel speed (km/h)

Lo (Low speed)

(Mi) (Middle 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

STRUCTURE AND FUNCTION


12
ATT

ELECTRONIC CONTROL SYSTEM

FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT)

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

STRUCTURE AND FUNCTION


12
SYSTEM

ELECTRONIC CONTROL SYSTEM

COMPONENT PARTS

ENGINE REVOLUTION SENSOR

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

STRUCTURE AND FUNCTION


12
PPC

ELECTRONIC CONTROL SYSTEM

OIL PRESSURE SWITCH

1. Plug
2. Switch
3. Connector
Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure:

5.0 1.0 kg/cm2 (71 14 psi)

Resetting (OFF) Pressure:

3.0 0.5 kg/cm2 (42 7 psi)

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

STRUCTURE AND FUNCTION


12
PUMP

ELECTRONIC CONTROL SYSTEM

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

STRUCTURE AND FUNCTION


12
PUMP

10-172

ELECTRONIC CONTROL SYSTEM

CONTROLLER

PC400LC-7L

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12
Input and output signals
CN-1

CN-2

Pin No.

Signal name

NC

R pump pressure sensor

3
4

Input/ Output

Pin No.

Signal name

Input/ Output

NC

Swing emergency switch

Input

NC

NC

Input

NC

232C_RxD

Input

NC

NC

NC

NC

NC

Model selection 4

F boom pressure sensor

Attachment circuit selector signal

NC

NC

10

Signal GND

10

NC

11

Knob SW

12

NC

13

Buchet CURL PPC pressure sensor

14

NC

15

NC

16

NC

17

Starting switch (Terminal C)

18

NC

19

Arm IN PPC pressure sensor

20

NC

21

NC

22

POT_PWR

23

Starting switch (terminal ACC)

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

Travel steering signal pressure SW

Input

17

Model selection 3

Input

18

NC

19

Auto deceleration signal

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

GND (pulse GND)

30

NC

31

GND (S_NET GND)

32

CAN0_H

33

NC

34

GND (232C GND)

35

Service valve pressure switch

36

NC

37

Model selection switch 1

Input

38

Swing lock switch

Input

39

GND (pulse GND)

40

Engine speed sensor

Input
Input
Input
Input

Input
Output

Output

Input

Input

Input/ output

Input

Input

10-173

STRUCTURE AND FUNCTION

ELECTRONIC CONTROL SYSTEM

12
CN-3
Pin No.

Signal name

Input/Output

VB (controller power)

Input

VIS (solenoid power)

Input

SOL_COM (solenoid common gnd)

Battery relay drive

NC

LS-EPC

Output

Travel junction SOL

Output

NC

NC

Input

10

Boom RAISE pressure SW

Input

11

VB (controller power)

Input

12

VIS (solenoid power)

Input

13

SOL_COM (solenoid common gnd)

Input

14

KEY_SIG

Input

15

NC

16

PC-EPC

Output

17

Pump merge/divider solenoid

Output

18

Heater relay drive

Output

19

Bucket DUMP pressure switch

Input

20

Boom LOWER pressure switch

Input

21

GND (controller GND)

Input

22

NC

23

SOL_COM (solenoid common gnd)

Input

24

KEY_SIG

Input

25

NC

26

Service flow adjustment EPC (1)

Output

27

Travel Hi/Lo selector solenoid

Output

28

2-stage relief solenoid

Output

29

Swing pressure switch

Input

30

Arm IN pressure switch

31

NC

Input

32

GND (controller GND)

Input

33

GND (controller GND)

Input

34

NC

35

NC

36

NC

37

Swing parking brake solenoid

38

NC

39

Travel pressure switch

Input

40

Arm OUT pressure switch

Input

10-174

Output

Output

PC400LC-7L

STRUCTURE AND FUNCTION

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.

Monitor section to output alarms when the machine has troubles

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

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

Washer motor output

Output

NC

Input

Starting signal

Input

NC

Input

Limit switch (W)

Input

NC

Input

GND

NC

Input

GND

VB +

RS230C CTS

Input

Input

RS230C RXD

Input

Wiper motor (+)

Output

RS230C RXD

Input/Output

10

Wiper motor (-)

Output

10

RS230C RXD

Input/Output

11

Buzzer ON signal

Input

11

BOOTSW

Input

12

Limit switch (P)

Input

12

NC

Input

13

GND

14

CAN (SHIELD)

Input

15

CAN (+)

Input

16

CAN (-)

Input

CN-2
Pin No.

Signal name

Input/output

Engine coolant temperature

Input

Fuel level

Input

Radiator coolant level

Input

(Hydraulic oil level)

Input

Air cleaner clogging

Input

NC

Input

Engine oil pressure

Input

Engine oil level

Input

N/W signal

Input/Output

10

N/W signal

Input/Output

11

Battery charge

Input

12

Hydraulic oil temperature (analog)

Input

13

GND (for analog signal)

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

STRUCTURE AND FUNCTION


12
MONITOR

MONITOR SYSTEM

CONTROL, DISPLAY PORTION

MONITOR PORTION

10-178

1. Wiper motor

11. Fuel level monitor

2. Preheating monitor

12. Hydraulic oil temperature monitor

3. Swing lock monitor

13. Power max. monitor

4. Engine coolant temperature monitor

14. Auto-deceleration monitor

5. Hydraulic oil temperature gauge

15. Radiator coolant level caution

6. Engine coolant temperature gauge

16. Battery charge caution

7. Working mode monitor

17. Engine oil pressure caution

8. Service monitor

18. Engine oil level caution

9. Travel speed monitor

19. Air cleaner clogging

10. Fuel gauge

20. Maintenance time warning caution

PC400LC-7L

STRUCTURE AND FUNCTION


12
MONITOR

MONITOR SYSTEM

ITEMS AND DISPLAY

Symbol

Display item

Swing lock

Preheating

Power Max

Display method
Swing lock switch

Swing holding brake release


switch

Swing lock monitor

OFF

OFF

OFF

ON

OFF

ON

OFF

ON

Flashes

ON

ON

ON

Continuous set time

Preheating monitor status

Up to 30 sec.

ON

From 30 sec. to 40 sec.

Flashes

More than 40 sec.

OFF

Power Max. switch status

Power Max. monitor status

Being pressed

Lights up but goes out after approx. 9 sec when kept pressed

Not being pressed

Flashes

Engine coolant
temperature
Hydraulic
oiltemperature

See gauge display on the next page

Fuel level

PC400LC-7L

10-179

STRUCTURE AND FUNCTION

MONITOR SYSTEM

12

Gauge

Engine coolant
temperature (C)

Hydraulic oil temperature (C)

Fuel level (l)

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

STRUCTURE AND FUNCTION

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

Check before starting


item

When engine is stopped

When engine is running

Engine oil pressure

---

When abnormal, lights up and


buzzer sounds

Battery charge

---

Lights up when abnormal

Radiator coolant level

Lights up when abnormal

When abnormal, lights up and


buzzer sounds

Engine oil level

Lights up when abnormal

---

Air cleaner clogging

---

Lights up when
abnormal

Maintenance

Lights up when there is a warning. Lights up for only 30 sec.


after key is turned ON, then goes out.

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

Condition of hydraulic oil

Color of symbol

Low temperature (below B6 or equivalent)

Black on white background

Normal (B6 B2)

No display

High temperature (below B2)

White on red background

10-181

STRUCTURE AND FUNCTION

MONITOR SYSTEM

12

Display
category

Symbol

Display item

Display range

Display method

Wiper

Displays set condition

Working mode

Displays set mode

Travel speed

Displays set speed

Monitor

Service meter

10-182

Auto-deceleration

ON OFF

Displays actuation status

Service meter
indicator

When service meter is working

Lights up when service


meter is working

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

MONITOR SYSTEM

12

Working mode selector switch


The condition of the machine changes
according to the switch that is pressed (A, E, L,
B). It is possible to check the condition on the
working mode monitor display. The relationship
between each working mode and the monitor
display is shown in the table on the right.

Switch that is pressed

Display

Working mode status after setting

[A]

A mode (default)

[E]

E mode

[L]

Heavy-lift mode

[B]

Swing priority mode

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

Low speed (default)

Crawler symbol + Mi

Medium speed

Crawler symbol + Hi

High speed

Travel speed selector switch


Each time the travel speed selector switch is pressed, the travel speed changes. Lo Hi Lo
Use the travel speed monitor display to check the present condition.
The relationship between the set speed and the monitor display in the table on the right.

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

Wiper actuation status

None

OFF

Stowing stopped or now stowing

Wiper symbol + INT

INT

Intermittent actuation

Wiper symbol + ON

ON

Continuous actuation

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION


12
SELECT

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

[A] + crusher symbol

E mode

[E] + crusher symbol

B mode

[B] + flow symbol

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

Flow level bar graph extends to the right

Flow level bar graph retracts to the left

C. After completing the level selection, press input confirmation


switch (3). The selection flow level is confirmed and the
screen moves to the normal screen. From the moment that the
flow level is selected, the content of the selection is reflected
for the attachment flow.
Before the input confirmation switch is pressed, the flow
level is not confirmed, so press return switch (4) to return
to the normal screen. This function can be used to return
to the previously set flow. The relationship between the
set flow level and the flow value is as shown in the table
on the right.

10-186

Flow level

Flow (L/min.)

Remarks

530

Default

430

370

300

230

165

100

30

PC400LC-7L

STRUCTURE AND FUNCTION

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.

10-key pad operation

01

02

03

C. After completing the level selection, press input confirmation


switch (3). The selected flow level is selected.
Before the input confirmation switch is pressed, the flow
level is not confirmed, so press return switch (4) to return to
the operator screen. This function can be used to return to the
previously set flow.
D. After the flow level is confirmed, the screen changes to the screen
shown in the diagram on the right. With this screen, it is possible
to make fine adjustment to the flow.

No.

Flow level (L/min.)

Remarks

01

230

Default

02

190

03

150

E. Press control switch (2) and select the flow level.


Control switch

Actuation

Flow level bar graph extends to the right

Flow level bar graph retracts to the left

PC400LC-7L

10-187

STRUCTURE AND FUNCTION

MONITOR SYSTEM

12
F.

After completing the level selection, press input confirmation


switch (3).
The selected flow level is confirmed and the screen moves to
the operator screen. From the moment that the flow level is
selected, the content of the selection is reflected for the
attachment flow.
Before the input confirmation switch is pressed, the flow
level is not confirmed, se press return switch (4) to return
to the normal screen. This function can be used to return
to the previously set flow. The relationship between the
set flow level and the flow value is as shown in the table
on the right.

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 When flow


is 140 L/ is 220 L/
min.
min.

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

Set value (L/min.)

220 or 360

200 or 340

180 or 320

160 or 300

140 or 280

120 or 260

100 or 240

80

PC400LC-7L

STRUCTURE AND FUNCTION


12
MAINTENANCE

MONITOR SYSTEM

FUNCTION

When the maintenance time for replacement, inspection, or filling has


approached for the 10 maintenance items, press maintenance switch (1)
and the caution display (yellow or red) appears on the monitor display for
30 seconds after the starting switch is turned ON to remind the operator to
perform lubrication maintenance.
Maintenance items
No.

Item

Replacement interval (hours)

01

Engine oil

500

02

Engine oil filter

500

03

Fuel filter

500

04

Hydraulic filter

1000

05

Hydraulic tank breather

500

06

Corrosion resistor

1000

07

Damper case oil

1000

08

Final case oil

2000

09

Machinery case oil

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

Notice display (black symbol displayed on yellow background)

There is one or more items with less than 30 hours remaining time for
maintenance

Warning display (wiper symbol displayed on red background)

There is one or more items with less than 0 hours remaining time for
maintenance

PC400LC-7L

10-189

STRUCTURE AND FUNCTION

MONITOR SYSTEM

12
METHOD OF CHECKING STATUS
MAINTENANCE ITEMS
Operate as follows when on the operator screen.
1.

Press maintenance switch (1) and switch to the maintenance list


display screen.
The maintenance items are displayed as symbols on the screen.

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.

After completing the selection, press input confirmation switch (3).


The screen will change to the maintenance reset screen.

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.

Check the content on the check screen, and if there is no problem,


press input confirmation switch (3) to reset the maintenance time.
After the reset is completed, the screen returns to the maintenance list
display screen. To check the remaining time, or if the wrong item is
selected, press return switch (4) to return to the maintenance list
screen.
The check screen shows the symbol for the maintenance item and
the set time in large letters.
The background color of the symbol for the item where the
maintenance item was reset is the same as the background of the
screen, so it is possible to check that it has been reset.

10-190

PC400LC-7L

STRUCTURE AND FUNCTION

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

Flow level bar graph extends to the right

Flow level bar graph retracts to the left

PC400LC-7L

10-191

STRUCTURE AND FUNCTION


12
SERVICE

MONITOR SYSTEM

METER CHECK FUNCTION

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.

DISPLAY LCD CHECK FUNCTION

On the password input screen or on the normal screen, if monitor


return switch (1) and working mode (A) switch are kept pressed at the
same time, all the LCD display will light up and the whole screen will
become white, so the display can be checked.
If any part of the display is black, the LCD is broken.

10-192

PC400LC-7L

STRUCTURE AND FUNCTION

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

STRUCTURE AND FUNCTION

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

Engine oil level

Name of sensor

Contact

ON (closed)

OFF (open)

Engine oil pressure

Contact

OFF (open)

ON (closed)

Hydraulic oil temperature

Resistance

---

---

Coolant temperature

Resistance

---

---

Fuel level

Resistance

---

---

Contact type

OFF (open)

ON (closed)

Air cleaner clogging

ENGINE OIL LEVER SENSOR

ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)

10-194

PC400LC-7L

STRUCTURE AND FUNCTION


12
COOLANT

SENSOR

TEMPERATURE SENSOR

HYDRAULIC OIL TEMPERATURE SENSOR

1. Thermistor

4. Tube

2. Body

5. Wire

3. Tube

6. Connector

FUEL LEVEL SENSOR

PC400LC-7L

10-195

STRUCTURE AND FUNCTION

SENSOR

AIR CLEANER CLOGGING SENSOR

10-196

PC400LC-7L

20

TESTING, ADJUSTING AND


TROUBLESHOOTING

STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2


STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
TROUBLESHOOTING
TROUBLESHOOTING GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) . . . . . . . . . . . . 20-601

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

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE

12

STANDARD VALUE TABLE FOR ENGINE

Item
Engine speed

Engine
Measurement condition
High idling
Low idling
Rated speed

Intake air pressure

At rated output

Exhaust gas pressure

Valve clearance
(normal temperature)

All speed range (intake air temp: 20C)


At sudden acceleration
At high idling
Intake valve
Exhaust valve

Compression
pressure

Oil temperature: 40-60C


(Engine speed)

Exhaust gas color

(Coolant temperature: within operating


range) At rated output
(Coolant temperature: within operating
range)
At high idling (SAE30)
Oil pressure
At high idling (SAE10W)
At low idling (SAE30)
At low idling (SAE10W)
Oil temperature
All speed range (inside oil pan)
Fan, alternator belt
Deflection when pressed with finger
tension
force of Approximately 58.8 N {6 kg}
Air conditioner
Deflection when pressed with finger
compressor belt tension force of approximately 58.8 N {6 kg}
Blow-by 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

Min 107 {Min. 800}

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)

Min. 2.9 {Min. 30}


(150-200)

2.0 {20}
(150-200)

kPa
{mmH2O}

Max. 1.18 {Max. 120}

1.96 {200}

MPa
{kg/cm2}

0.39-0.69 {4.0- 7.0}


0.34-0.64 {3.5-6.5}
Min. 0.15 {Min. 1.5}
Min. 0.1 {Min. 1.0}

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

For further detailed information, refer to Engine Shop Manual

20-2 1

PC400LC-7L

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12

STANDARD VALUE TABLE FOR CHASSIS


Cate
gory

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

Boom control lever

15.7 4.9
{1.6 0.4}

Max. 24.5
{Max. 2.5}

Arm control lever

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}

Engine water temperature: Within

operating range

2 pumps at relief

Hydraulic oil temperature: Within

operating range

Engine speed

Engine at high idling


Arm in relief condition
Engine water temperature: Within

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

Operating effort of control levers

Travel of control levers Spool stroke

Speed when auto


deceleration is
operated

Engine at high idling


Auto-deceleration switch in ON

condition

All control levers in NEUTRAL

condition

Boom control valve


Arm control valve
Bucket control valve
Swing control valve
Travel control valve
Boom control lever
Arm control lever
Bucket control lever
Swing control lever
Travel control lever
Play of control levers

Bucket control lever


Swing control lever
Travel control: Lever
Travel control: Pedal

PC400LC-7L

rpm

Engine stopped
At center of control lever grip
Max. reading up to stroke end

(excepting lever play in NEUTRAL


position)

Hydraulic oil temperature: Within

operation range

Engine at high idling


Hydraulic oil temperature: Within

operating range
At center of control lever grip
Max. reading up to stroke end

N {kg}

20-3 1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12
Category

Item

Unload pressure

Measurement conditions

Unit

Hydraulic oil temperature: Within


operation range
Engine at high idling
Working mode: A mode
Hydraulic pump output pressure with all
control levers in NEUTRAL position

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

{340-375 (365- 400)}

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)}

Working mode: A mode


Hydraulic pump output pressure with all
measurement circuits relieved
Values inside parenthesis: Hydraulic oil
pressure with one-touch power max.
switch in ON mode (reference only)

-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

{340-375 (365- 400)}


33.34-36.77

(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}

Hydraulic oil temperature: Within


operation range
Engine at high idling
Self-reducing pressure valve output
pressure with all control levers in
NEUTRAL position

3.24 0.2
{33 2}

2.84-3.43
{29-35}

Hydraulic oil temperature: Within


operation range
Engine at high idling

When all
control levers
in NEUTRAL
position

4.2 1.0
{42 10}

4.2 1.0
{42 10}

Working mode: A mode When travTraveling speed: Hi


eling at half
stroke
Hydraulic oil pump
(without load)
pressure-LS pressure

2.65 0.1
{27 1}

2.65 0.1
{27 1}

-0.98

Travel

-10

Control circuit source


pressure

LS differential pressure

20-4 1

PC400LC-7L

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12
Category

Item

Swing brake angle

Measurement conditions

Hydraulic oil temperature: Within operating

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

Hydraulic oil temperature: Within

sec.

operation range

Bucket: Empty
Engine at high idling
Working mode: A mode
Time required for passing points 90

180

Swing

and 180 degrees from starting point

Time taken to swing Hydraulic oil temperature: Within operating


range
Bucket: Empty
Engine at high idling
Working mode: A mode
Time required for 5 more turns after making
initial one turn

Hydraulic drift of
swing

Hydraulic oil temperature: Within operation

range

Engine stopped
Keeping upper structure transverse on slope of

15 degrees

Notching a mating mark on inner and outer

races of swing circle

Mating mark misalignment amount during 5

minutes

PC400LC-7L

20-5 1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

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

Hydraulic oil temperature: Within

Leakage from swing


motor

operation range

Engine at high idling


Swing lock switch: ON
Leakage amount for one minute during

swing relief

Travel speed
(Idle travel)

Travel

Travel speed
(Actual travel)

Travel deviation

20-6 1

Hydraulic oil temperature:

Within operation range


Engine at high idling
Working mode: A mode
Time required for track shoes to
make 5 turns after making one
initial idle turn

Hydraulic oil temperature:

Within operation range


Engine at high idling
Working mode: A mode
Flat ground
Time required for traveling 20 m
after 10 m trial run

sec.

Mi

sec.

Hi

Hydraulic oil temperature: Within


operation range
Engine at idling
Working mode: A mode
Travel speed: Lo
Solid and flat ground
Swerving amount while traveling 20 m
(X) after initial 10 m trial run.

mm

PC400LC-7L

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12
Category

Item

Unit

Standard value

Permissible value

mm

L/min

Max. 20

Max. 40

Whole work equipment


(tooth tip fall amount)

Max. 600

Max. 900

Boom cylinder (cylinder


retraction amount)

Max. 25

Max. 38

Max. 85

Max. 128

Max. 30

Max. 45

Travel

Hydraulic drift of travel

Measurement conditions

Hydraulic oil temperature: Within

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

Engine at high idling


Travel: Lock sprocket.
Oil leakage amount for one minute with

Hydraulic drift work equipment

Work equipment

traveling in relief condition

Arm cylinder (cylinder


extension amount)

Hydraulic oil temperature: Within

operation range

Flat and level ground


Work equipment in measurement

posture as illustrated above


Bucket load: 3,060 kg (6746.15 lb)
Bucket cylinder (cylinder Engine stopped
Work equipment control lever in
retraction amount)
NEUTRAL position
Fall amount for 15 minutes as measured
every 5 minutes starting immediately
after initial setting

PC400LC-7L

mm

20-7 1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

Standard value for


new machine

Service limit value

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

Hydraulic oil temperature: Within

operation range

Engine at high idling


Working mode: A mode
Time required from raise stroke

Work equipment speed

Work equipment

end till bucket touches ground

Arm

Hydraulic oil temperature: Within

operation range

Engine at high idling


Working mode: A mode
Time required from dumping

sec.

stroke end to digging stroke end

Bucket

Hydraulic oil temperature: Within

stroke end to digging

DUMP

operation range

Engine at high idling


Working mode: A mode
Time required from dumping
stroke end

20-8 1

PC400LC-7L

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

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

Hydraulic oil temperature: Within operation

range

Engine at low idling


Working mode: A mode
Time required from raise stroke end till bucket

Time lag

Work equipment

touches ground and pushes up machine front

Arm

Hydraulic oil temperature: Within operation

sec.

range

Engine at low idling


Working mode: A mode
Time required from dumping stroke end till

bucket stops momentarily after control lever is


tilted to digging and starts to move again

Bucket

Hydraulic oil temperature: Within operation

range

Engine at low idling


Working mode: A mode
Time required from dumping stroke end till

Internal leackage

bucket stops momentarily after control lever is


tilted to digging and starts to move again

Cylinders

Center swivel
joint

PC400LC-7L

Hydraulic oil temperature: Within operation

range

Engine at high idling


Leakage amount for one minute with cylinder

or travel to be measured in relief condition

cc/min

20-9 1

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12
Category

Item

Measurement Condition

Unit

Standard value

Permissible value

mm

Max. 400

Max. 440

Performance in compound operation

Swerving amount in
simultaneous operation
of work equipment and
travel

Performance of hydraulic pump

Hydraulic oil temperature: Within

Hydraulic pump
delivery

operation range

20-10 1

Engine at high idling


Working mode: A mode
Traveling speed: Lo
Flat and level ground
Swerving amount (X) when traveling

20 m after initial trial run of 10 m

See next page

L/min

See next page

PC400LC-7L

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12

Item

Measurement Condition

Check point

Test pump discharge Discharge pressure


pressure
of other pump
(MPa {kg/cm2})
(MPa {kg/cm2})

Unit

Standard value

Permissible
value

Performance of hydraulic pump

Category

As desired

P1

P2

Average pressure
(MPa {kg/cm2})

P1+P2
2

Standard value for


discharge amount Q
(L/min)

See graph

Judgement standard lower


limit Q (L/min)

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

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR CHASSIS

12

MEMORANDUM

20-12 1

PC400LC-7L

TESTING AND ADJUSTING

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

TESTING AND ADJUSTING

SERVICE TOOLS

12

Measuring intake air pressure (boost pressure)


Measuring exhaust temperature

A
B

Part No.

1
Measuring exhaust gas color

Adjusting valve clearance

D
1

Measuring compression pressure

E 2
3

Measuring blow-by pressure

Boost gauge kit


Digital thermometer
Handy smoke meter

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

Measuring fuel pressure

2
Measuring clearance of swing circle bearing

Measuring and adjusting oil pressures in work K


equipment, swing, and travel circuits

1
2
1

Measuring basic pressure in control circuit

L
2

Testing and adjusting oil pressure in pump PC M


control circuit

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

1 -101 - 200 kPa {-760 - 1,500 mmHg}


1 -99.9 - 1,299C
1 Pollution level: 0 - 70 % (With
standard color) (Pollution level x 1/10
1 Bosch index)
intake side: 0.35 mm, Exhaust side:
1 Air
0.57 mm
1 0 - 6.9 MPa {0 - 70 kg/cm2}
1
For 125E-3 engine
1
1

(Pressure gauge): 2.5, 5.9, 39.2, 58.8


MPa {25, 60, 400, 600 kg/cm2}
(Pressure gauge): 58.8 MPa {600 kg/
Digital hydraulic tester 1
cm2}
(Pressure gauge): 0.98MPa {10 kg/
Hydraulic tester
1
cm2}
Hydraulic tester
1
Digital hydraulic tester 1 Same as G
Hydraulic tester
1

Same as G
(Size): 10 x 1.25 mm
Same as G1
Same as K2
Same as G

PC400LC-7L

TESTING AND ADJUSTING

SERVICE TOOLS

Part No.
1

Testing and adjusting pressure in pump LS


control circuit

2
3
1

Measuring solenoid valve output pressure

P
2

Measuring PPC valve output pressure

1
2

Measuring oil leakage

Testing wear of sprocket


Measuring water temperature and oil temperature

-----

Measuring operating effort and pressing force

---

Measuring stroke and hydraulic drift

---

Measuring work equipment speed

---

Measuring voltage and resistance

---

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

TESTING AND ADJUSTING

MEASURING ENGINE SPEED

12

MEASURING ENGINE SPEED


1.

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.

Measure the engine speed under each measurement condition.


A. Measuring low idling speed:
i.

Start the engine and set the fuel control dial in the low idling
position (MIN).

ii.

Set the work equipment control, swing control, and travel


levers in neutral and measure the engine speed.

B. Measuring high idling speed:


i.

Start the engine and set the fuel control dial in the high idling position (MAX).

ii.

Set the working mode switch in the A-mode position.

iii. Turn the auto-decelerator switch OFF.


iv. Set the work equipment control, swing control, and travel levers in neutral.
C. Measuring 2-pump relief speed:
i.

Start the engine and set the fuel control dial in the high idling position (MAX).

ii.

Set the working mode switch in the A-mode position.

iii. Relieve the arm circuit by moving the arm in.


D. Measuring 2-pump relief + one-touch power maximizing speed (near rated speed):
i.

Start the engine and set the fuel control dial in the high idling position (MAX).

ii.

Set the working mode switch in the A-mode position.

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.

Turn the auto-deceleration switch ON.

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

TESTING AND ADJUSTING

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

ADJUSTING ENGINE SPEED SENSOR


ADJUSTING VALVE CLEARANCE
BLOW-BY PRESSURE
COMPRESSION PRESSURE
ENGINE OIL PRESSURE
ENGINE SPEED SENSOR
EXHAUST GAS COLOR
EXHAUST TEMPERATURE
INTAKE AIR PRESSURE (BOOST PRESSURE)

PC400LC-7L

20-105 1

TESTING AND ADJUSTING

FAN BELT AND ALTERNATOR BELT TENSION

12

FAN BELT AND ALTERNATOR BELT TENSION


TESTING
1.

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.

Loosen bolts and nuts (1), (2), and (3).

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.

Tighten nuts and bolts (3), (2), and (1).


If a V-belt is replaced, adjust its tension again after 1 operating hour.

20-106 1

PC400LC-7L

TESTING AND ADJUSTING

AIR CONDITIONER COMPRESSOR BELT TENSION

12

AIR CONDITIONER COMPRESSOR BELT TENSION


TESTING
1.

Open the engine hood and remove belt protection covers (2 pieces).

2.

Press the intermediate point between air conditioner compressor


pulley and crank pulley with a finger and measure deflection a of the
belt.
Deflection a when pressing force is approximately 58.8 N
{approximately 6 kg}: 14 mm - 16 mm

ADJUSTING
If the deflection is abnormal, adjust it according to the following
procedure.
1.

Loosen bolts (1) and (2).

2.

Move compressor (3) to adjust the belt tension.


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.

Tighten bolts (2) and (1).


If a V-belt is replaced, adjust its tension again after 1 operating hour.

PC400LC-7L

20-107 1

TESTING AND ADJUSTING

SWING CIRCLE BEARING CLEARANCE

12

SWING CIRCLE BEARING CLEARANCE


Measuring instrument for clearance of swing circle bearing.
When measuring the clearance of the swing circle bearing on the
actual machine, observe the following procedure.
WARNING! While measuring, do not put your hands or
foot under the undercarriage.
1.

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.

Set the dial gauge to 0 point.

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.

Under this condition, read dial gauge J.


Dial gauge J indicates the clearance of the bearing.

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

TESTING AND ADJUSTING

TRACK SHOE TENSION

12

TRACK SHOE TENSION


TESTING
1.

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.

Measure maximum distance a between square bar [1] and track


shoe.
Standard maximum distance a: 10 - 30 mm

ADJUSTING
If the track shoe tension is abnormal, adjust it according to the
following procedure.
1.

When tension is too high


Loosen valve (3) to discharge the grease.
WARNING! Since the valve may jump out because of
the high-pressure grease, do not loosen it
more than 1 turn.

2.

When tension is low


Add grease through valve (3).
If the track shoe is not tensed well, drive the machine forward and in reverse slowly.

PC400LC-7L

20-109 1

TESTING AND ADJUSTING

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS

12

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS


Testing and adjusting instruments for oil pressure in work equipment,
swing, and travel circuits.
Symbol
1
K
2

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

The pump oil pressure is displayed in 1 kg/cm2 (1 psi).

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

TESTING AND ADJUSTING

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS

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.

Measuring unload pressure


A. Start the engine.
B. Run the engine at high idling and set all the control levers in
neutral and measure the oil pressure.
The pressure measured when the unload valve is unloaded is
indicated.

4.

Measuring work equipment circuit relief pressure


A. Start the engine and move the cylinder to be measured to the
stroke end.

(F unload valve) (F main relief valve)


Service Safety valve for service
Boom Hi F main relief valve
Arm Hi
Bucket
F main relief valve
Front
Left travel F main relief valve
RAISE: F main relief
valve
Boom
LOWER: Safety-suction
valve
(Pump merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
Swing
Swing motor safety valve
Rear
Right travel R main relief valve
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)

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.

Measuring swing circuit relief pressure


A. Start the engine and turn the swing lock switch ON.
B. Run the engine at high idling and relieve the swing circuit and measure the oil pressure.
The pressure measured when the swing motor safety valve is relieved is indicated.
The swing motor relief pressure is lower than the main relief valve.

6.

Measuring travel circuit relief pressure


A. Start the engine and lock the travel mechanism.
WARNING! Set pin [2] between the sprocket and track
frame to lock the travel mechanism
securely.
B. Run the engine at high idling and relieve the travel circuit and
measure the oil pressure.
The pressure measured when the main relief valve is relieved
is indicated. The travel circuit is always relieved at high
pressure.

PC400LC-7L

20-111 1

TESTING AND ADJUSTING

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS

12
ADJUSTING
The unload valve cannot be adjusted.
1.

Adjusting main relief pressure


If the relief pressure of the work equipment circuit and/or travel
circuit is abnormal, adjust main relief valves (3) and (4) according
to the following procedure.
(3): Front main relief valve
(4): Rear main relief valve
When adjusting the main relief valve on the front pump side,
remove the control valve top cover.
When adjusting the main relief valve on the rear pump side,
remove the control valve undercover (if the covers are installed).
Adjust only the low relief pressure of the main relief valve. (If the
low relief pressure is adjusted, the high relief pressure is adjusted
automatically.)
The low relief pressure is the pressure applied when the 2-stage
relief solenoid valve is turned OFF and the pilot pressure is not
applied to the selector port.
A. Disconnect pilot hose (5).
B. Fixing holder (6), loosen locknut (7).
C. Turn holder (6) 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 209 kg/cm2, (2972 psi)
D. Fixing holder (6), tighten locknut (7).
Locknut: 49.0 - 58.8 Nm (36.1 - 43.3 lbf ft)
E. Connect pilot hose (5).
F.

2.

After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.

Adjustment of boom LOWER relief pressure (High-pressure setting


side)
If the high relief pressure of the boom LOWER circuit is abnormal, adjust the high pressure setting side of boom LOWER safety
suction valve (8) according to the following procedure.
The high relief pressure is the pressure applied when the machine
push-up switch is turned ON and the pilot pressure is not applied
to the selector port.
A. Disconnect pilot hose (9).
B. Fixing holder (10), loosen locknut (11).

20-112 1

PC400LC-7L

TESTING AND ADJUSTING

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS

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.

After finishing adjustment, check again that the pressure is normal


according to the procedure for measurement described above.
If the high pressure setting side is adjusted, the low pressure
setting side changes. Accordingly, adjust the low pressure
setting side.

Adjustment of boom LOWER relief pressure (Low-pressure setting


side)
If the low relief pressure of the boom LOWER circuit is abnormal or the high pressure setting side was adjusted,
adjust the low pressure setting side of boom LOWER safety-suction valve according to the following procedure.
The low relief pressure is the pressure applied when the machine push-up switch is turned OFF and the pilot pressure
is applied to the selector port.
A. Disconnect pilot hose (9).
B. Fixing holder (12), loosen locknut (13).
C. Turn holder (12) 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 (12), tighten locknut (13).
Locknut: 78 - 93 Nm (57.5 - 68.5 lbf ft)
E. Connect pilot hose (9).
F.

4.

After finishing adjustment, check again that the pressure is normal according to the procedure for measurement
described above.

Adjusting swing relief pressure


If the relief pressure of the swing circuit is abnormal, adjust swing
motor safety valve (14) according to the following procedure.
A. Fixing adjustment screw (15), loosen locknut (16).
B. Turn adjustment screw (15) to adjust the pressure.
If the adjustment screw is:
turned to the right, the pressure rises.
turned to the left, the pressure lowers.
Quantity of adjustment per turn of adjustment screw:
47.9 kg/cm2 (681 psi).

PC400LC-7L

20-113 1

TESTING AND ADJUSTING

WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS

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

TESTING AND ADJUSTING

CONTROL CIRCUIT - BASIC PRESSURE

12

CONTROL CIRCUIT - BASIC PRESSURE


Measuring instruments for basic pressure in control circuit
Symbol
1
L
2

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.

Install nipple L2 and connect it to oil pressure gauge [1] of hydraulic


tester L1.
Use the oil pressure gauges of 60 kg/cm2 (853.4 psi)

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.

After finishing measurement, remove the measuring instruments and


return the removed parts.
The relief valve for the control circuit basic pressure is not
adjustable.

PC400LC-7L

20-115 1

TESTING AND ADJUSTING

PUMP PC CONTROL CIRCUIT

12

PUMP PC CONTROL CIRCUIT


Testing and adjusting instruments for oil pressure in pump PC control circuit
Symbol
1
M
2

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.

Measuring PC valve output pressure (servo piston inlet pressure)


Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and
compare them.
A. Open the pump room cover and remove oil pressure pick-up plugs
(1), (2), (3), and (4).
(1): Front pump discharge pressure pickup plug.
(2): Rear pump discharge pressure pickup plug.
(3): Front PC valve output pressure pickup plug.
(4): Rear PC valve output pressure pickup plug.

B. Install nipple M2 and connect it to oil pressure gauge [1] of


hydraulic tester M1.
Use the oil pressure gauges of 600 kg/cm2 (8534 psi).
The figure shows the pump discharge pressure side.

20-116 1

PC400LC-7L

TESTING AND ADJUSTING


12

PUMP PC CONTROL CIRCUIT

The figure shows the PC valve output pressure side.

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

TESTING AND ADJUSTING

PUMP PC CONTROL CIRCUIT

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).

B. Install nipple M2 and connect it to oil pressure gauge [1] of


hydraulic tester M1.
Use the oil pressure gauges of 60 kg/cm2 (853.4 psi).

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

TESTING AND ADJUSTING

PUMP PC CONTROL CIRCUIT

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.

Loosen locknut (8).


Before loosening the locknut, make match marks at the adjustment screw end so that you can see the position of the
locknut before the adjustment (and you can return the locknut to its original position after turning it in reverse).

2.

Turn adjustment screw (9) to the right or left to adjust.


Turn the adjustment screw in the following directions.
If the work equipment speed is low, turn the adjustment screw to the right (to increase the pump absorption
torque).
If the engine speed lowers, turn the adjustment screw to the left (to decrease the pump absorption torque).
The adjustable range of the adjustment screw is as follows.
Counterclockwise: Max. 1 turn.
Clockwise: Max. 1 turn.

3.

Tighten locknut (8).


Locknut: 27.5 - 34.3 Nm (20.2 - 25.2 lbf ft)

4.

After finishing adjustment, check that the PC valve output pressure


(servo piston inlet pressure) is normal according to the procedure for
measurement described above.

PC400LC-7L

20-119 1

TESTING AND ADJUSTING

PUMP LS CONTROL CIRCUIT

12

PUMP LS CONTROL CIRCUIT


Testing and adjusting instruments for oil pressure in pump LS control circuit
Symbol
1
N

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.

Measuring LS valve output pressure (servo piston inlet pressure)


Measure the LS valve output pressure (servo piston inlet pressure) and pump discharge pressure at the same time and
compare them.
A. Open the pump room cover and remove oil pressure pick-up plugs
(1), (2), (3), and (4).
(1): Front pump discharge pressure pickup plug.
(2): Rear pump discharge pressure pickup plug.
(3): Front LS valve output pressure pickup plug.
(4): Rear LS valve output pressure pickup plug.

B. Install nipple N2 and connect it to oil pressure gauge [1] of


hydraulic tester N1.
Use the oil pressure gauges of 600 kg/cm2 (8534 psi).
The figure shows the pump discharge pressure side.

20-120 1

PC400LC-7L

TESTING AND ADJUSTING


12

PUMP LS CONTROL CIRCUIT

The figure shows the LS valve output pressure side.

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

Pump discharge pressure


LS valve output pressure

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.

Measuring LS differential pressure


Measure the pump discharge pressure and LS pressure (actuator
load pressure) at the same time and calculate the difference
between them.
A. Open the pump room cover and remove oil pressure pick-up plugs
(1), (2), (5), and (6).
(1): Front pump discharge pressure pickup plug.
(2): Rear pump discharge pressure pickup plug.

PC400LC-7L

20-121 1

TESTING AND ADJUSTING


12

PUMP LS CONTROL CIRCUIT

(5): Front LS valve output pressure pickup plug.


(6): Rear LS valve output pressure pickup plug.

B. Install nipple N2 and connect it to differential pressure gauge N3


or the oil pressure gauge of hydraulic tester N1.
When using differential pressure gauge: Connect the pump
discharge pressure to the high pressure side (back side) and
connect the LS pressure to the low pressure side (lower side).
Since the differential pressure gauge needs a 12-V power
source, connect it to a battery.
When using oil pressure gauge: Use the oil pressure gauge of
600 kg/cm2 (8534 psi). Since the differential pressure is about
30 kg/cm2 (427 psi) at maximum, measure it by installing the
same gauge to the pick-up plugs alternately.
The figure shows the pump discharge pressure side.

The figure shows the LS valve output pressure side.

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

TESTING AND ADJUSTING

PUMP LS CONTROL CIRCUIT

12
3. Measuring LS-EPC valve output pressure.
A. Open the pump room cover and remove LSEPC valve output
pressure pick-up plug (7).

B. Install nipple N2 and connect it to oil pressure gauge [1] of


hydraulic tester N1.
Use the oil pressure gauges of 60 kg/cm2 (853 psi).

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

Fine operation (Remark)

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

TESTING AND ADJUSTING

PUMP LS CONTROL CIRCUIT

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.

Fixing adjustment screw (10), loosen locknut (11).

2.

Turn adjustment screw (10) to adjust the differential pressure.


If the adjustment screw is:
turned to the right, the differential pressure rises.
turned to the left, the differential pressure lowers.
Quantity of adjustment (LS differential pressure) per turn of
adjustment screw: Approximately 13.3 kg/cm2 (189 psi).

3.

After finishing adjustment, check that the LS pressure is normal


according to the procedure for measurement described above.

20-124 1

PC400LC-7L

TESTING AND ADJUSTING

SOLENOID VALVE - OUTPUT PRESSURE

12

SOLENOID VALVE - OUTPUT PRESSURE


Measuring instruments for solenoid valve output pressure
Symbol
1
P
2

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

Solenoid valve to be measured


2-stage relief solenoid valve
Machine push-up solenoid valve
Swing holding brake solenoid valve
Travel speed selector solenoid valve
Merge-divider solenoid valve
Travel junction solenoid valve
PPC lock solenoid valve

2.

Install adapter P2 and connect the disconnected hose again.

3.

Install nipple [1] of hydraulic tester P1 and connect it to hydraulic


gauge [2].
Use the oil pressure gauges of 60 kg/cm2 (853.4 psi).
The figure shows the measuring instruments connected to the
outlet hose of the 2-stage relief solenoid valve.

PC400LC-7L

20-125 1

TESTING AND ADJUSTING

SOLENOID VALVE - OUTPUT PRESSURE

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).

If the output pressure is as follows, the solenoid valve is normal.


Solenoid valve

Output pressure

OFF (Deenergized)

0 kg/cm (0 psi)

ON (Energized)

Almost same as control basic pressure (See standard values table)

6.

After finishing measurement, remove the measuring instruments and return the removed parts.

Operation table of 2nd-stage relief solenoid valve


Operating condition

Operation

When overheating No. 1 setting is turned ON

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

When boom LOWER signal is turned ON


When in A/E-mode

When signal other than swing single operation signal is turned


When left knob switch is turned ON ON
When swing single operation signal is turned ON

When not under above condition

OFF

Operation table of machine push-up solenoid valve


Operating condition
Machine push-up switch

OFF
ON

Operation
ON
OFF

Operation table of swing holding brake solenoid valve


Operating condition
When all are turned OFF
When one of them is turned ON

Work equipment,
swing, travel signal

20-126 1

Operation
OFF
ON

PC400LC-7L

TESTING AND ADJUSTING

SOLENOID VALVE - OUTPUT PRESSURE

12
Operation table of travel speed shifting solenoid valve
Operating condition

Operation

When overheating No. 2 setting is turned ON


When fuel control dial is below 1,200 rpm
When travel speed switch is set to Lo

OFF

When travel signal is turned OFF


When travel speed switch is set to Mi or Hi

When travel signal is turned ON

When F or R pump pressure is above 330 kg/


cm2 (4693 psi)
When F or R pump pressure is below 190
kg/cm2 (2702 psi)

ON

When not under above condition

Operation table of merge-divider solenoid valve


When in B-mode

When travel signal is turned


ON

When travel signal is turned


OFF

Operating condition
When service signal is turned ON
When travel operation is performed singly

When work equipment,


switch, and service
signals are turned ON

When swing signal is


turned OFF

Operation

When F or R pump pressure is above 200


kg/cm2 (2844 psi)
When not in L-mode
When F or R pump pressure is below 150
kg/cm2 (2133 psi)
When F or R pump pressure is above 170
kg/cm2 (2418 psi)
When in L-mode
When F or R pump pressure is below 120
kg/cm2 (1707 psi)
When arm IN and bucket When 2F or R pump pressure is above 250
CURL PPC pressures are kg/cm (3556 psi)
above 19.5 kg/cm2 (277 When F or R pump pressure is below 200
psi)
kg/cm2 (2844 psi)

ON

OFF
ON
OFF
ON
OFF

When not under above condition

Operation table of travel junction solenoid valve


Operating condition

Operation

When F or R pump pressure is above 350


When travel system is
kg/cm2 (4978 psi)
When travel steering signal is turned OFF operated singly
When not under above condition

ON

When travel steering signal is turned ON

OFF

Operation table of PPC lock solenoid valve


Operating condition
Lock
Safety lock lever
Free

PC400LC-7L

OFF
ON

20-127 1

TESTING AND ADJUSTING

PPC VALVE - OUTPUT PRESSURE

12

PPC VALVE - OUTPUT PRESSURE


Measuring instruments for PPC valve output pressure
Symbol
Q

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

TESTING AND ADJUSTING

PPC VALVE - OUTPUT PRESSURE

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

TESTING AND ADJUSTING

WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT

12

WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT


SWING PPC VALVE - PLAY ADJUSTMENT
If the work equipment and swing levers have large play, adjust them according to the following procedure.
1.

Remove the work equipment and swing PPC valve assembly.

2.

Remove bellows (1).

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.

Install bellows (1).

6.

Install the work equipment and swing PPC valve assembly.

20-130 1

PC400LC-7L

TESTING AND ADJUSTING

WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE

12

WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE


If the work equipment (cylinder) drifts hydraulically, check to see if the cause is on the cylinder packing side or control
valve side according to the following procedure.

1.

Testing boom cylinder and bucket cylinder.


A. Set the machine in the position of measuring hydraulic drift and
stop the engine.
Fill the bucket with a rated load or with dirt and sand.
B. When testing the boom cylinder, set the boom control lever in the
RAISE position. When testing the bucket cylinder, set the bucket
control lever in the CURL position.
If the lowering speed is increased at this time, the cylinder
packing is defective.
If the lowering speed does not change at this time, the control
valve is defective.
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.

2.

Testing arm cylinder.


A. Stop the arm cylinder about 100 mm before the IN stroke end and
stop the engine.

B. Operate the arm control lever in the IN position.


If the lowering speed is increased at this time, the cylinder
packing is defective.
If the lowering speed does not change at this time, the control
valve is defective.
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.
Remark
Reason why the lowering speed is increased by the above operation when the cylinder packing is the cause of the
hydraulic drift:
A. If the machine is set in the above position (where the holding pressure is applied to the bottom side), the oil leaks
from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the
volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side.
B. As the pressure in the head side is increased, it is balanced at a certain level (which depends on the leakage), and then
the lowering speed is lowered.
C. If the circuit on the head side is opened to the drain circuit by the above operation of the lever (the bottom side is
closed by the check valve at this time), the oil on the head side flows in the drain circuit. As a result, the pressure is
unbalanced and the lowering speed is increased.

PC400LC-7L

20-131 1

TESTING AND ADJUSTING

WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE

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

TESTING AND ADJUSTING

RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT

12

RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT


1.

Releasing residual pressure in hydraulic tank.


WARNING! Since the hydraulic tank is enclosed and pressurized, release the residual pressure in it
when removing a hose or a plug connected to it.
A. Lower the work equipment to the ground in a stable position and stop the engine.
B. Loosen oil filler cap (1) of the hydraulic tank gradually to release
the air in the tank.

2.

Releasing residual pressure in hydraulic cylinder circuit.


WARNING! When disconnecting a pipe between a
hydraulic cylinder and the control valve,
release the residual pressure in the piping
according to the following procedure.
A. Release the residual pressure in the hydraulic tank. For details, see
RELEASING RESIDUAL PRESSURE IN HYDRAULIC
TANK.
Keep the oil filler cap of the hydraulic tank removed.
B. Turn the starting switch ON and set the safety lock lever in the FREE position, and then operate the work equipment
control levers on both sides forward, backward, to the right, and to the left.
The control valve is operated by the pressure in the accumulator. The pressure in the accumulator is used up,
however, after the control valve is operated 2 - 3 times.
C. Run the engine at low idling for 5 seconds to heighten the pressure in the accumulator.
When starting engine, set the safety lock lever in the LOCK position.
D. Repeat steps B and C above 2 - 3 times, and the residual pressure in the piping is released.

3.

Releasing residual pressure in swing motor circuit.


The residual pressure in the swing motor circuit can be released by performing the operation for RELEASING
RESIDUAL PRESSURE IN HYDRAULIC CYLINDER CIRCUIT (Operate the lever in the swing direction only,
however).

4.

Releasing residual pressure in travel motor circuit.


Since the control valve spool of the travel motor circuit is open, the pressure in this circuit can be released by
performing RELEASING RESIDUAL PRESSURE IN HYDRAULIC TANK.

PC400LC-7L

20-133 1

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

12

MEASURING OIL LEAKAGE


Measuring device for oil leakage
Symbol
R

1.

Part No.
Commercially available

Part Name
Measuring cylinder

Measuring oil leakage from boom cylinder.


A. Run the engine and raise the engine oil temperature to the operating range.
B. Move the boom cylinder to the RAISE stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the boom cylinder head side. For details,
see RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in
the boom RAISE direction only, however).
C. Disconnect hose (1) 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 boom circuit by
raising the boom.
WARNING! Take care not to lower the boom.
E. Measure the oil leakage for 1 minute after 30 seconds since
relieving is started.
F.

2.

After finishing measurement, return the removed parts.

Measuring oil leakage from arm cylinder.


A. Run the engine and raise the engine oil temperature to the operating range.
B. Move the arm cylinder to the IN stroke end and stop the engine.
WARNING! Release the residual pressure in the piping on the arm cylinder head side. For details, see
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT (Operate the lever in the
arm IN direction only, however).
C. Disconnect hose (2) 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 arm circuit by
moving the arm IN.
WARNING! Take care not to move the arm OUT.
E. Measure the oil leakage for 1 minute after 30 seconds since
relieving is started.
F.

After finishing measurement, return the removed parts.

20-134 1

PC400LC-7L

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

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.

After finishing measurement, return the removed parts.

Measuring oil leakage from swing motor.


A. Run the engine and raise the engine oil temperature to the operating range.
B. Disconnect drain hose (4) and block the hose side with a plug.
Use the following part to block the hose side.
07376-70522 (Plug #05)
C. Turn the swing lock switch ON.
D. Run the engine at high idling and relieve the swing circuit by
swinging.
Measure the oil leakage for 1 minute after 30 seconds since
relieving is started.
After measuring 1 time, swing 180, and then measure again.
E. After finishing measurement, return the removed parts.

PC400LC-7L

20-135 1

TESTING AND ADJUSTING

MEASURING OIL LEAKAGE

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

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

12

BLEEDING AIR FROM EACH PART

Work
Replacing hydraulic oil

1
Air bleeding item
Bleeding air
from
hydraulic
pump

Replacing return filter element


Replacing and repairing hydraulic pump
Removing suction piping
Replacing and repairing control valve
Removing control valve piping
Replacing and repairing cylinder
Removing cylinder piping
Replacing and repairing swing motor
Removing swing motor piping
Replacing and repairing travel motor
Removing travel motor piping
Replacing and repairing swivel joint
Removing swivel joint piping

2
Starting
engine

Air bleeding procedure


4

air
Bleeding air Bleeding
swing
from cylinder from
motor

Bleeding air
from travel
motor

Check oil level and


starting work

(See Remark) (See Remark)

Remark
Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1.

Bleeding air from hydraulic pump.


A. Loosen bleeder (1) and check that oil flows out.
B. If the oil does not flow out, disconnect drain hose (2) and fill the
pump case with oil through the drain port.
Fix the drain hose adapter to a place higher than the oil level
in the hydraulic tank.
Fill the pump case with oil until oil containing no bubbles
flows out of the bleeder.
C. After oil containing no bubbles flows out of bleeder (1), tighten
air bleeder (1).
Air bleeder: 7.8 - 9.8 Nm (5.75 - 7.22 lbf ft)
If the drain hose has been disconnected, connect it after tightening the air bleeder.

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

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

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.

Bleeding air from swing motor.


A. Run the engine at low idling.
B. Loosen hose (3) of port S slowly and check that oil flows out.
WARNING! At this time, do not perform the swinging
operation.
C. If the oil does not flow out, stop the engine and disconnect the
hose of port S and fill the pump case with oil.
After filling the pump case with oil, connect the hose of port
S, and then repeat steps A and B.
D. After oil containing no bubbles flows out, tighten the hose of port
S.
E. Swing slowly 2 turns or more in each direction.

5.

Bleeding air from travel motor.


A. Remove the travel motor cover.
B. Run the engine at low idling.
C. Loosen bleeder (4) and check that oil flows out.
D. After oil containing no bubbles flows out, tighten bleeder (4).
Bleeder: 9.8 - 12.74 Nm (7.22 - 9.39 lbf ft)
E. Using the work equipment, raise the track shoe on either side.
F.

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

TESTING AND ADJUSTING

BLEEDING AIR FROM EACH PART

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

TESTING AND ADJUSTING

DIODE TESTING PROCEDURE

12

DIODE TESTING PROCEDURE


Test an assembled-type diode or a diode unit according to the
following procedure.
The conductive direction of an assembled-type diode is marked as
shown in the figure.
The conductive direction of each diode is marked on its surface.
1.

When using a digital tester.


A. Set the tester in the diode range and check the indicated value.
If an ordinary tester is used, the voltage of the battery in itself
is indicated.
B. Apply the red (+) test pin to the anode (P) side of the diode and
the black () test pin to the cathode (N) side and read the indicated
value.

C. Judge the condition of the diode from the indicated value.


The indicated value does not change: There is not continuity
(Defective).
The indicated value changes: There is continuity (Normal)
(Remark).
Remark
In the case of a silicon diode, the tester indicates a value of 460
600.
2.

When using an analog tester.


A. Set the tester in the resistance range.
B. Apply the test pins as shown below and check movement of the
pointer.
i.

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.

C. Judge the condition of the diode from movement of the pointer.


The pointer does not move in i above but moves in ii: Normal
(Moving angle (Resistance) depends on the type and
measurement range of the tester, however)
The pointer moves in both i and ii: Defective (Internal short circuit)
The pointer does not move in either of i and ii: Defective (Internal disconnection)

20-140 1

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

12

MONITOR PANEL - SPECIAL FUNCTIONS

[1] Numeral input switch 1


[2] Numeral input switch 2
[3] Numeral input switch 3
[4] Numeral input switch 4
[5] Numeral input switch 5

PC400LC-7L

[6] Numeral input switch 6


[7] Numeral input switch 7
[8] Numeral input switch 8
[9] Numeral input switch 9
[0] Numeral input switch 0

[/
[
[
[

] Return switch
] Move-up switch
] Move-down switch
] Input check switch

20-141 1

TESTING AND ADJUSTING


12
ORDINARY

MONITOR PANEL - SPECIAL FUNCTIONS

FUNCTIONS AND SPECIAL FUNCTIONS OF MONITOR PANEL

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.

Ordinary functions: Operator menu


The items in this menu are displayed normally. The operator can display and set them by operating switches.

2.

Special functions: Service menu


The items in this menu are not displayed normally. Each serviceman can display them by operating special switches.

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

TESTING AND ADJUSTING


12
OPERATION

MONITOR PANEL - SPECIAL FUNCTIONS

AND DISPLAY OF OPERATORS MENU

(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.

Screen to display KOMATSU logo.


When a password is input (if it is set) or when the starting switch is
turned ON, the KOMATSU logo is displayed for 2 seconds.

2.

Function of check before starting.


After the KOMATSU logo is displayed, the screen for check before
starting is displayed for 2 seconds.

3.

Function of displaying maintenance items.


After the screen for check before starting is displayed, if any oil or
filter is near or has passed the set maintenance time, the maintenance
mark is displayed for 30 seconds.
This screen is displayed only when the maintenance function is
set.

4.

Function of displaying caution items.


After the screen for check before starting is displayed, if any check
item is abnormal, the corresponding symbol mark is displayed.

PC400LC-7L

20-143 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

Function of displaying ordinary screen.


After the screen for checking the working mode and travel speed is
displayed, the ordinary screen is displayed.
When the ordinary screen is displayed, if the working mode or
travel speed is changed or if the auto deceleration or windshield
wiper is set effective, the corresponding symbol mark is displayed
in large size for 2 seconds.
The preheating monitor is displayed only when the pre-heater is
turned ON.

7.

Function of adjusting brightness and contrast of display.


The operator can adjust the brightness and contrast of the display with
the screen adjustment switches.

8.

Function of adjusting flow rate for breaker and attachments (for


machine with breaker or attachment).
The operator can adjust the pump flow rate for the breaker or an
attachment wit h the selector switch.
The symbol marks and description of the breaker and attachment
shown on the screen are partly different.

20-144 1

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

10. Function of displaying service meter.


When the starting switch is turned OFF, the operator can display only
the service meter by operating the following switches.
Operation of switches: [/] + [] (Operate these switches
simultaneously)

11. Function of checking display LCD.


On the password inputting screen or ordinary screen, the operator can
check the display LCD.
Operation of switches: [/] + [A] (Operate these switches
simultaneously)
The whole LCD unit is turned ON and all the surface becomes
white. If there is not any black part, the LCD unit is normal.
If any switch is operated while the LCD unit is being checked, the
screen before the check is displayed again.

12. Function of displaying cautions.


If there is any abnormal one in the calculation items, the
corresponding symbol mark is displayed in large size for 2 seconds,
and then it is displayed in small size until the abnormal item is
repaired.

PC400LC-7L

20-145 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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).

User codes and instructions given to operator


User code

Failure mode

E02

Error in pump control system

E03

Error in swing brake system

E10
E11
E14
E15
E0E

20-146 1

Error in engine controller power supply


or abnormality in engine controller
drive system circuit (Engine stops)
Error in engine controller system
(Engine protection output is down)
Error in throttle system
Error in engine sensor (water
temperature, fuel temperature, or oil
pressure)
Error in network

Instructions given to operator


If the emergency pump drive switch is set in the upper (emergency) position, the
machine can operate normally. Have the machine inspected immediately, however.
Set the swing holding brake release switch in the upper (release) position to release
the brake. Apply the swing brake manually with the swing lock switch, if necessary.
The brake may not be released, depending on the cause of the failure. In any case,
have the machine inspected immediately.
Have the machine inspected immediately.
Set the machine in a safe position and have the machine inspected immediately.
Set the machine in a safe position and have the machine inspected immediately.
Although the machine can operate normally, have the machine inspected
immediately.
Set the machine in a safe position and have the machine inspected immediately.

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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

(2) Phone No.

(3) Error code and failure code

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

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

12
Table for Error and Failure Code Nos.

-----------

E112
E113
E114
E115
E116

Wiper Drive (For) S/C


Wiper Drive (Rev) S/C
Washer Drive S/C
Wiper Working Abnormality
Wiper Parking Abnormality

DY2DKB
DYDEKB
DY2CKB
DY20KA
DY20MA

Wiper motor (Forward)


Wiper Motor (Reverse)
Windshield Washer Motor
Wiper Motor
Wiper Motor

---

E117 Eng. Controller S-NET Comm Err.

DAC0KR

Engine Controller

---

E118 Pump Controller S-NET Comm Err. DAB0KR

Pump Controller

E128 Monitor Comm. Abnormality

DAFRMC

E201 Travel Junction Sol. S/C

DW91KB

E03

E203 Swing Brake Sol. S/C

DW45KB

---

E204 Merge-divider Sol. S/C

DWJ0KB

---

E205 2-stage Relief Sol. S/C

DWK0KB

---

E206 Travel Speed Sol. S/C

DW43KB

---

E211 Travel Junction Sol. Disc.

DW91KA

E03

E213 Swing Brake Sol. Disc.

DW45KA

---

E214 Merge-divider Sol. Disc.

DWJ0KA

---

E215 2-stage Relief Sol. Disc.

DWK0KA

---

E216 Travel Speed Sol. Disc.

DW43KA

---

E217 Model Selection Abnormality

DA2SKQ

E218 S-Net Comm. Disc.

DA2SKA

---------

E222
E223
E224
E225

DXE0KB
DXE0KA
DHPAMA
DHPBMA

---

E226 Press. Sensor Power Abnormality

DA25KP

----E02

E227 Engine Speed Sensor Abnormality


E228 Service Return Relay S/C
E232 PC-EPC Sol. S/C

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

LS-EPC Sol. S/C


LS-EPC Sol. Disc.
F Pump P. Sensor Abnormality
R Pump P. Sensor Abnormality

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

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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

---

E248 Bucket Curl PPC Sen. Abnormality

DHS4MA

---

E251 Overload Sensor Abnormality

DHX1MA

E257 Pump Comm. Abnormality

DA2RMC

---

E315 Battery Relay Drive S/C

D110KB

Pump Controller CAN


Communication
Battery Relay

E11

E91B Engine Ne Sensor Problem

DLE3LC

NE Speed Sensor

E11

E91C Engine G Sensor Problem

DLH1LC

G Speed Sensor

E11

E920 Engine Type Selection Error

DB29KQ

Engine Controller Model


Selection Wiring Harness

E11

E921 Engine Type Mismatch

DB20KQ

Engine Controller

E14

E931 Fuel Dial sys. error

DK10KX

E15

E934 Engine Coolant Sensor Hi Error

DGE2KX

Throttle Angle Sensor


Engine Coolant Temperature
Sensor

E15

E936 Engine Oil Press. Sw. Error

DDE2L6

Engine Oil Pressure Switch

E11
E15

E93C Engine Boost Sensor Error


E93D Engine Fuel Temp. Sensor Error

DH30KX
DGE4KX

E0E

E953 Engine Comm. Abnormality

DB2RMC

E954 Short Engine Starter SW.

DD11KB

E0E

E955 Engine S-NET error

DB2SMC

E10

E956 Engine Power Failure (1)

DB22KK

E15

E957 Engine Power Failure (2)

D1D0KB

---

E95A Engine Q-adj. Sw. Signal Error

DB2AMA

E15

E96A Engine Coolant Sensor Lo Error

DGE3L6

E11
E11
E11
E11
E11

E970
E971
E974
E975
E977

AD11KB
AD51KB
AD11KA
AD51KA
DH40KX

Boost Pressure Sensor


Fuel Temperature Sensor
Engine Controller CAN
Communication
Starter SW.
Engine Controller S-NET
Communication
Engine Controller Load Power
Supply Line
Engine Controller Load Power
Supply Relay
Rotary Switch in Engine
Controller
Engine Coolant Temperature
Sensor
Supply Pump (1) Solenoid Valve
Supply Pump (2) Solenoid Valve
Supply Pump (1) Solenoid Valve
Supply Pump (2) Solenoid Valve
Common Rail Pressure Sensor

E0E

---

PCV1 Over Current


PCV2 Over Current
PCV1 Line Cut
PCV2 Line Cut
Rail Press. Sensor Error

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

E979 Rail Press. High 1

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

Rail Press. High 2


Rail press. low
Rail press. too low
Rail Press. Out of Control
Eng. Controller Abnormality
Fuel Injector 1 Disc.
Fuel Injector 2 Disc.
Fuel Injector 3 Disc.
Fuel Injector 4 Disc.
Fuel Injector 5 Disc.
Fuel Injector 6 Disc.
Fuel Injector 1 - 3 S/C
Fuel Injector 4 - 6 S/C
Eng. Hi Out of Std
Eng. Lo Out of Std
Aircleaner Clogging
Charge Voltage Low
Eng. Oil Press. Low
Eng. Oil LvI. Low
Eng. Water Overheat
Eng. Water Lvl Low
Hydr. Oil Overheat

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

Abnormally High Fuel


Pressure
Common Rail
Malfunction
Supply Pump
Out of control
Supply Pump
Lowering of Function
Supply Pump
Malfunction
Engine Controller
Abnormality in Controller
Injector 1 Solenoid Valve
Disconnection
Injector 2 Solenoid Valve
Disconnection
Injector 3 Solenoid Valve
Disconnection
Injector 4 Solenoid Valve
Disconnection
Injector 5 Solenoid Valve
Disconnection
Injector 6 Solenoid Valve
Disconnection
Injector 1, 2, 3 Solenoid Valve Short Circuit
Injector 4, 5, 6 Solenoid Valve Short Circuit
Engine
Overrun
Engine
Out of input signal range
Air Cleaner Element
Clogging
Alternator
Defective Charge
Engine Oil
Lowering of Oil Pressure
Engine Oil
Lowering of level
Coolant
Overheating
Coolant
Lowering of level
Hydraulic Oil
Overheating
Common Rail

Electrical
system

User
code

12

MONITOR PANEL - SPECIAL FUNCTIONS

Mechanical system

TESTING AND ADJUSTING

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

TESTING AND ADJUSTING


12
OPERATION

MONITOR PANEL - SPECIAL FUNCTIONS

AND DISPLAY OF SERVICE MENU

How to select service menu


When using the service menu, perform the following special operation
to change the screen.
A. Checking display.
Check that the ordinary screen is displayed.
The service menu can be selected only while the ordinary
screen is displayed.

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

D. Finishing menu and function.


To finish the service menu screen or each menu screen, perform one of the following operations.
(1) Press the [/] switch (This operation is effective on all screens).
(2) When the Return switch is displayed, press it.
(3) When the Return menu is displayed, select it and press the [] switch.

PC400LC-7L

20-151 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

B. Setting monitoring items.


Select and register monitoring items with the following switches.
[] switch: Select
[] switch: Select
[] switch: Register
You can set up to 4 monitoring items (You cannot set up to 4
monitoring items, however, depending on the selected items).
When monitoring up to 3 items, go to the monitoring
information screen by either of the following operations after
registering those items.
Hold the [] switch (for about 3 seconds).
Select menu 99999 and press the [] switch.
If all of the settleable items are registered, the monitoring information screen appears automatically after
registering those items.
For the detail, display units, etc. of the monitoring items, see the monitoring items table.
C. Operating for monitoring.
After the monitoring information screen appears, operate the
machine to check the monitoring information.

20-152 1

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

E. Function of selecting machine setting mode.


To change settings of the working mode, travel speed, or auto
deceleration during the monitoring operation, press the switches
for those items, and the mode checking screen appears.
After checking the settings, press the [] switch, and the
monitoring screen appears again.
If the settings are changed during the monitoring operation,
the new settings are held even after monitoring is finished
and the service menu disappears and the operator menu
appears again.

PC400LC-7L

20-153 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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

Unit (Default: ISO)


SI
meter
(Not displayed)
(Not displayed)
Numerals
Numerals
r/min
rpm
r/min
rpm
MPa
kg/cm2
MPa
kg/cm2

07200
07300
04102
14200
04401
01300
01500
01700
03200
03500
04300
01006
04107
36400

Arm Curl PPC Pressure


Bucket Curl PPC Pressure
Engine Water Temp. Hi
Fuel Temperature
Hydr. Oil Temperature
PC-EPC Sol. Curr.
LS-EPC Sol. Curr.
Service Sol. Curr.
Battery Voltage
Battery Relay O/P Vol.
Battery Charge Vol.
Engine Speed
Engine Water Temp. Low
Rail Pressure

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

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

Unit (Default: ISO)


SI
meter
inch
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF

Remarks

20-155 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

12
Codem No.

Monitoring item

17400

Eng. Controller Input

36800
36801

Q Adjust Switch R (ROT-SW1)


Q Adjust Switch L (ROT-SW2)

05100

S-NET Connection

20200
20212
20209

Monitor Prog. Version


Pump Con. Prog. Version
Eng. Con. Prog. Version

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

Unit (Default: ISO)


meter
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
Alphanumerals
Alphanumerals
ON/OFF
ON/OFF
Numerals
Numerals
Numerals

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

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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

Sub-menu of abnormality record


Return (Finish sub-menu)
Electrical systems
Mechanical systems

C. Contents of electrical system abnormality record screen


[1]: Reverse sequential order/Total number of records
[2]: Error code
[3]: Failure code (Component: 4 characters, Trouble: 2 characters)
[4]: Advance of service meter after 1st occurrence
[5]: Contents of failure
See Error codes and failure codes table in the operator
menu.

D. Contents of mechanical system abnormality record screen


[1]: Record No.
[2]: Contents of failure
[3]: Failure code (Component: 4 characters, Trouble: 2 characters)
[4]: Total number of occurrences
[5]: Service meter reading at 1st occurrence
See Error codes and failure codes table in the operator
menu.

PC400LC-7L

20-157 1

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

While the electrical system abnormality record screen is


displayed, operate the following switches to display the reset
screen.
Operation of switches: [] + [1] [2] [3]
This operation is the same as that for selecting the service
menu.

ii.

Operate the switches according to the direction shown on the


reset screen.
When resetting only 1 item, be sure display it with the []
switch or [] switch, and then perform the reset
procedure.
When resetting all the items, you can perform the reset
procedure, regardless of the item displayed on the screen.

20-158 1

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

18. Function of maintenance mode change [04].


The condition for setting the operation of the maintenance display
function can be changed according to the following procedure.
Set the function effective or ineffective.
Change the set replacement interval.
A. Selecting menu.
On the initial screen of the service menu, select 04 Maintenance
Mode Change and press the [] switch.

B. Selecting item to be changed.


On the screen of maintenance mode changing menu, select an
item to be changed.
No.
00
01
02
03
04
05
06
07
08
09
10
11
12

Item of maintenance mode change


Return
Use/Disuse maintenance mode
Replacement interval of engine oil
Replacement interval of engine oil filter
Replacement interval of fuel filter
Replacement interval of hydraulic oil filter
Replacement interval of hydraulic tank breather
Replacement interval of corrosion resistor (if equipped)
Check and refill interval of damper case oil
Replacement interval of final drive case oil
Replacement interval of machinery case oil
Replacement interval of hydraulic oil
Return all items to initial values

PC400LC-7L

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TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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).

D. Contents of setting of each item.


i.

Default: Maintenance time set in monitor. (Value


recommended by manufacturer. Constant value.)

ii.

Set value: Maintenance time which operation can set freely.


Monitor panel operates according to this value in
maintenance mode. (This value can be changed by 50 hours
with [] and [] switches.)

iii. Off: Function of displaying this maintenance item becomes


ineffective.
iv. On: Function of displaying this maintenance item becomes
effective.
The lower limit of the set time is 50 h.
E. Contents of setting Return all items to initial values.
If this menu is selected and the [] switch is pressed, all the information items are changed to the initial values.

20-160 1

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

B. Selecting input screen.


Select Entry to display the phone No. input screen.
Even if a phone No. has been registered, if the phone No.
input screen is displayed, the registered phone No. is cleared.

C. Inputting and setting phone No.


On the phone No. input screen, input a phone No. according to the
following procedure (The phone No. is input from the cursor at
the left end automatically).
i.

Input a No. with the numeral keys from the cursor at the left
end.

ii. After finishing inputting the No., press the [] switch.


Up to 12 digits can be input. You do not need to input a digit
to an unnecessary place, however.
If you input a wrong No., press the [B] switch, and the cursor
returns 1 place by 1.
If the phone No. is input, the Entry screen above is
displayed again. If the phone No. is displayed on this screen, it is input normally.

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TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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

Sub-menu of initial value/default


Return (Finish initial value/default)
Key-on mode
Language
Unit
With/Without service circuit

C. Function of selecting mode when key is ON.


When the starting switch is turned ON, a working mode is
displayed on the monitor panel. The operator can change this
working mode.
A-mode, E-mode, L-mode, B-mode: If any of these mode is
set, the machine is started in the selected mode when the
starting switch is turned ON.
Mode when key was turned off last: If this mode is set, the
machine is started in the mode used last when the starting
switch is turned ON.
Initial value: If this mode is set, the machine is started in the
default mode set in the factory when the starting switch is
turned ON.
If the machine having an attachment is stopped in the B-mode, it is started in the B-mode when the starting
switch is turned ON next time, regardless of this setting.

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TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

E. Function of selecting unit.


The operator can select 1 of the 3 unit systems as the unit system
used for the data displayed by the monitoring function of the
service menu.
The default unit system of the monitor panel is the SI unit
system.

F.

Function of selecting with/without service circuit.


The operator can set with/without service circuit.
With service circuit: When attachment is installed.
Without service circuit: When attachment is not installed.
When an service circuit is installed, if With service circuit
is not set on this screen, the operator cannot use the select
function (adjustment of oil flow for the attachment) in the
operator mode.

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MONITOR PANEL - SPECIAL FUNCTIONS

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

C. Function of pump absorption torque.


The operator can adjust the pump absorption torque within the
ranges shown in the following table.
Adjustment
value
220
221
222
223
224

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

D. Function of adjustment of oil flow for attachment in compound


operation.
The operator can adjust the oil flow for the attachment in
compound operation within the ranges shown in the following
table.
Adjustment value
370
371
372
373

20-164 1

Oil flow for attachment


0.5 times
0.7 times
1.0 times
0.4 times

PC400LC-7L

TESTING AND ADJUSTING

MONITOR PANEL - SPECIAL FUNCTIONS

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.

B. Setting cylinders to be disabled.


Press switches [1] - [6] on the monitor panel corresponding to the
cylinder Nos. to be disabled.
After a switch is pressed, if the cylinder No. corresponding to
it on the monitor panel is displayed white in a white frame,
the cylinder is disabled (If setting is wrong, press the same
switch again).
Only one or more cylinders can be disabled for the reduced
cylinder mode operation.

C. Cancellation of disabled cylinders.


Press switches [1] - [6] on the monitor panel corresponding to the
disabled cylinder Nos. to cancel disabling of those cylinders.
After a switch is pressed, if the cylinder No. corresponding to
it on the monitor panel is displayed black in a black frame,
disabling of the cylinder is cancelled.

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MONITOR PANEL - SPECIAL FUNCTIONS

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.

[Reference]: How to use holding function effectively


The engine speed displayed by the holding function is held on the screen
until the holding function is cancelled, regardless of setting and
cancellation of the cylinder cut out mode. Accordingly, a defective cylinder
can be found out effectively according to the following procedure.
1.

Run the engine normally (without disabling any cylinder) and hold the
engine speed.

2.

Disable a cylinder to be checked.

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.

5. Repeat steps (2) - (4) to check the other cylinders.


If the engine speed does not lower at all or lowers less when a cylinder
is selected for the cylinder cut out mode operation, combustion in that
cylinder must be abnormal.

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PC400LC-7L

TESTING AND ADJUSTING

HANDLING OF ENGINE CONTROLLER

12

HANDLING OF ENGINE CONTROLLER


WARNING! The engine controller has a high-voltage
circuit (110 - 130 V) to drive the fuel
injector. This circuit is connected to the
wiring harness and connectors between
the engine controller and fuel injector.
Normally, the engine controller outputs the high voltage to the fuel
injector only while the engine is running and stops outputting if the
engine stops.
WARNING! If you touch the high-voltage circuit directly, you may get an electric shock. To avoid this,
observe the following precautions.
1.

The following connectors are used in the high voltage circuit.


Engine controller connector: CB3.
Junction connector: ER03.
Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6.
Injector head terminal (in head cover).

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.

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PREPARATION WORK FOR TROUBLESHOOTING

12

PREPARATION WORK FOR TROUBLESHOOTING


When carrying out troubleshooting for an electric circuit related to the
monitor panel, engine controller, or pump controller, expose the
related connectors according to the following procedure.
1.

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.

B. Remove the 3 mounting screws and disconnect monitor panel (2)


from the mount.
Take care not to drop the mounting screws in the console.
C. Insert or connect T-adapters in or to connectors P01, P02, P70 of
the monitor panel.

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)

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TESTING AND ADJUSTING

PREPARATION WORK FOR TROUBLESHOOTING

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).

B. Insert or connect T-adapters in or to connectors C01, C02, and


C03 of the pump 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)

PC400LC-7L

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TESTING AND ADJUSTING

PM CLINIC SERVICE

12

PM CLINIC SERVICE

20-170 1

PC400LC-7L

TESTING AND ADJUSTING

PM CLINIC SERVICE

12
Positions to install measuring devices (Related to engine)

PC400LC-7L

20-171 1

TESTING AND ADJUSTING

PM CLINIC SERVICE

12
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)

20-172 1

PC400LC-7L

TESTING AND ADJUSTING

PM CLINIC SERVICE

12

PC400LC-7L

20-173 1

TESTING AND ADJUSTING

PM CLINIC SERVICE

12

20-174 1

PC400LC-7L

TESTING AND ADJUSTING

PM CLINIC SERVICE

12

Pm-CLINIC SERVICE PC400 (LC)


Visual check of welded structures
If any crack is found, draw its shape below.

Arm

Boom

Revolving frame

1. Arm cylinder bracket


Left
Right
2. Arm foot

4. Boom top bracket


Left
Right
5. Boom cylinder bracket

9. Boom bracket
Left
Right

Left
3. Arm top boss
Left

PC400LC-7L

Right
Right

End plate

Left

Right

6. Arm cylinder bracket


Left
Right
7. Boom lower plate
Left
Right
8. Boom foot
Left
Right

Track frame
10. Circle bracket
Front
Left

Rear
Right

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TESTING AND ADJUSTING

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

POINTS TO REMEMBER WHEN TROUBLESHOOTING

12

POINTS TO REMEMBER WHEN TROUBLESHOOTING


WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot water may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

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.

Points to ask user or operator


A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F.

3.

Has the same kind of failure occurred before?

Check before troubleshooting


A. Check the oil level
B. Check for any external leakage of oil from the piping or hydraulic equipment.

PC400LC-7L

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TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

C. Check the travel of the control levers.


D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4.

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.

A. Start from the simple points.


B. Start from the most likely points.
C. Investigate other related parts or information.
6.

Measures to remove root cause of failure


Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To
prevent this, always investigate why the problem occurred. Then, remove the root cause.

20-204 b

PC400LC-7L

TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

12

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC400LC-7L

20-205 b

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

12

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE


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

POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT


HANDLING WIRING HARNESSES AND CONNECTORS
Wiring harnesses consist of wiring connecting one component to another
one, connectors used for connecting and disconnecting one wire from
another wire, and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring
harnesses are more likely to be affected by the direct effects of rain, water,
heat, or vibration. Furthermore, during inspection and repair operations,
they are frequently removed and installed again, so they are likely to suffer
deformation or damage. For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
MAIN FAILURES OCCURRING IN WIRING HARNESS
1.

Faulty Contact of Connectors, Faulty Contact Between Male and


Female
Problems with faulty contact are likely to occur because the male
connector is not properly inserted into the female connector, or
because one or both of the connectors is deformed or the position is
not correctly aligned, or because there is corrosion or oxidation of the
contact surfaces.

2.

Faulty Crimping or Soldering of Connectors


The pins of the male and female connectors are in contact at the
crimped terminal or soldered portion, but if there is excessive force
brought to bear on the wiring, the plating at the joint will peel and
cause improper connection or breakage.

20-206 b

PC400LC-7L

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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.

High Pressure Water Entering Connector


The connector is designed to make it difficult for water to enter, drip
proof structure, but if high pressure water is sprayed directly on the
connector, water may enter the connector, depending on the direction
of the water jet. As already said, the connector is designed to prevent
water from entering, but at the same time, if water does enter, it is
difficult for it to be drained. Therefore, if water should get into the
connector, the pins will be short-circuited by the water, so if any water
gets in immediately dry the connector or take other appropriate action
before passing electricity through it.

5.

Oil or Dirt Stuck to Connector


If oil or grease are stuck to the connector and an oil film is formed on
the mating surface between the male and female pins, the oil will not
let the electricity pass, so there will be faulty contact. If there is oil or
grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
When wiping the mating portion of the connector, be careful not
to use excessive force or deform the pins.
If there is oil or water in the compressed air, the contacts will
become even dirtier, so remove the oil and water from the
compressed air completely before cleaning with compressed air.

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TROUBLESHOOTING
12
REMOVING,

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES

DISCONNECTING CONNECTORS
1.

Hold the Connectors When Disconnecting


When disconnecting the connectors hold the connectors and not the
wires. For connectors held by a screw, loosen the screw fully, then
hold the male and female connectors in each hand and pull apart. For
connectors which have a lock stopper, press down the stopper with
your thumb and pull the connectors apart. Never pull with one hand.

2.

When Removing from Clips


When removing a connector from a clip, pull the connector in a
parallel direction to the clip.
If the connector is twisted up and down or to the left or right, the
housing may break.

3.

Action to Take after Removing Connectors


After removing any connector, cover it with a vinyl bag to prevent any
dust, dirt, oil, or water from getting in the connector portion.
If the machine is left disassembled for a long time, it is
particularly easy for improper contact to occur, so always cover
the connector.

20-208 b

PC400LC-7L

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

12
CONNECTING CONNECTORS
1.

Check the Connector Visually


A. Check that there is no oil, dirt, or water stuck to the connector pins
(mating portion).
B. Check that there is no deformation, faulty contact, corrosion, or
damage to the connector pins.
C. Check that there is no damage or breakage to the outside of the
connector.
If there is any oil, water, or dirt stuck to the connector, wipe it off
with a dry cloth. If any water has got inside the connector, warm
the inside of the wiring with a dryer, but be careful not to make it
too hot as this will cause short circuits.
If there is any damage or breakage, replace the connector.

2.

Fix the Connector Securely


Align the position of the connector correctly, then insert it securely.
For connectors with lock stopper, push in the connector until the
stopper clicks into position.

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.

If the connector clamp has been removed, be sure to return it to its


original position. Check also that there are no loose clamps.

5.

Connecting connectors (DT type connector)


Since the DT 8-pole and 12-pole DT type connectors have 2 latches
respectively, push them in until they click 2 times.
A. Male connector, 2. Female connector
Normal locking state (Horizontal): a, b, d
Incomplete locking state (Diagonal): c

PC400LC-7L

20-209 b

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

CONTROL BOX

1.

The control box contains a microcomputer and electronic control


circuits. These control all of the electronic circuits on the machine, so
be extremely careful when handling the control box.

2.

Do not open the cover of the control box unless necessary.

3.

Do not place objects on top of the control box.

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

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS

1.

Always turn the power OFF before disconnecting or connect connectors.

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.

POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT


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

BE CAREFUL OF THE OPERATING ENVIRONMENT


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

DISASSEMBLY AND MAINTENANCE WORK IN THE FIELD


If disassembly or maintenance work is carried out on hydraulic equipment
in the field, there is danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs, so it is desirable to use
unit exchange. Disassembly and maintenance of hydraulic equipment
should be carried out in a specially prepared dust proof workshop, and the
performance should be confirmed with special test equipment.

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

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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.

CHANGE HYDRAULIC OIL WHEN THE TEMPERATURE IS HIGH.


When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit
together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old
hydraulic oil must be drained out. Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the
drain plug in the circuit. If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the
life of the hydraulic oil.

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

CHECKS BEFORE TROUBLESHOOTING

12

CHECKS BEFORE TROUBLESHOOTING


Item

Lubricating
oil, coolant

Electrical
equipment
Hydraulic
mechanical
equipment

Electronics,
electrical
equipment

1. Check fuel level, type of fuel


2. Check for impurities
3. Check hydraulic oil level
4. Check hydraulic strainer
5. Check swing machinery oil level
6. Check engine oil level, type of oil
7. Check coolant level
8. Check dust indicator for clogging
9. Check hydraulic filter
10. Check final drive oil level
1. Check for looseness, corrosion of battery terminal, wiring
2. Check for looseness, corrosion of alternator terminal, wiring
3. Check for looseness, corrosion of starter motor terminal, wiring
1. Check for abnormal noise, smell
2. Check for oil leakage
3. Carry out air bleeding
1. Check battery voltage, engine stopped
2. Check battery electrolyte level
3. Check for discolored, burnt, exposed wires
4. Check for missing wiring clamps, hanging wiring
5. Check for water leaking on wiring (be particularly careful attention to water
leaking on connectors or terminals)
6. Check for blown, corroded fuses
7. Check alternator voltage, throttle or above
8. Check operating sound of battery, when switch is turned On/Off

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

---

Disconnect and dry

Action

--Replace
After running
for several
Replace
minutes:
27.5 to 29.5 V
--Replace

PC400LC-7L

TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

12

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING


CLASSIFICATION OF TROUBLESHOOTING
Mode
Code display
E mode
H mode
S mode

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

STEPS FOR TROUBLESHOOTING


If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting No. and proceed
to the explanations for diagnosis.
1.

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

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CONSIDERED TO BE FAILURES AND TROUBLESHOOTING

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

Phenomena considered to be failures

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

CLASSIFICATION AND STEPS FOR 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

Phenomena considered to be failures

Display of
code
Possible faults related to work equipment

E-mode

Speed or power of boom is low


Speed or power of arm is low
Speed or power of bucket is low
Work equipment does not move singly
Hydraulic drift of work equipment is large
Time lag of work equipment is large
When a work equipment device is relieved singly, other work equipment device
moves
One-touch power maximizing function does not work
E-6
Machine push-up function does not work normally
E-7
Attachment circuit is not selected (when attachment is installed)
E-8
Oil flow in attachment circuit cannot be adjusted (when attachment is installed)
Possible faults related to compound operation
In compound operation of work equipment, speed of part loaded more is low
When machine swings and raises boom simultaneously, boom rising speed is low
When machine swings and travels simultaneously, travel speed lowers largely
Possible faults related to travel
Machine deviates during travel
Travel speed is low
Machine is not steered well or steering power is low
Travel speed does not change or it is lower or higher than set speed
Travel motor does not work (only 1 side)
Travel alarm does not sound or does not stop sounding
E-31
Possible faults related to swing
Machine does not swing
Swing acceleration or swing speed is low
Upper structure overruns remarkably when it stops swinging
Large shock is made when upper structure stops swinging
Large sound is made when upper structure stops swinging
Hydraulic drift of swing is large
Possible faults related to monitor panel (Operator menu: Ordinary screen)
No items are displayed on monitor panel
E-9
Some items are not displayed on monitor panel
E-10
Items displayed on monitor panel are not matched to machine model
E-11
Fuel level monitor lights red while engine is running
E-12

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

CLASSIFICATION AND STEPS FOR 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

Phenomena considered to be failures

Display of
code

E-mode

H-mode

S-mode

Engine coolant temperature gauge does not indicate normally


E-13
Hydraulic oil temperature gauge does not indicate normally
E-14
Fuel level gauge does not indicate normally
E-15
Swing lock monitor does not indicate normally
E-16
When monitor switches are operated, no items are displayed
E-17
Windshield wiper or windshield washer does not operate
E-18
Alarm buzzer cannot be cancelled
E-19
Possible faults related to monitor panel (Service menu: Special function screen)
Monitoring function does not indicate Boom RAISE normally.
E-20
Monitoring function does not indicate Boom LOWER normally.
E-21
Monitoring function does not indicate Arm IN normally.
E-22
Monitoring function does not indicate Arm OUT normally.
E-23
Monitoring function does not indicate Bucket CURL normally.
E-24
Monitoring function does not indicate Bucket DUMP normally.
E-25
Monitoring function does not indicate Swing normally.
E-26
Monitoring function does not indicate Travel normally.
E-27
Monitoring function does not indicate Travel differential pressure
E-28
normally.
Monitoring function does not indicate "Service" normally.
E-29
Other failure
Air conditioner does not operate (Troubleshooting for air conditioner
E-31
system)

PC400LC-7L

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

CONNECTOR ARRANGEMENT DRAWING


CONNECTORS LIST
The address of each connector roughly shows the place of the connector in the connectors stereogram and the circuit
diagram of each system.
Connector
No.

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

CONNECTOR ARRANGEMENT DRAWING

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

CONNECTOR ARRANGEMENT DRAWING

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

CONNECTOR ARRANGEMENT DRAWING

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

CONNECTOR ARRANGEMENT DRAWING

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

CONNECTOR ARRANGEMENT DRAWING

LOCATION DIAGRAM

PC400LC-7L

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

PC400LC-7L

20-225 b

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

20-226 b

PC400LC-7L

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

PC400LC-7L

20-227 b

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

20-228 b

PC400LC-7L

TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING

12

PC400LC-7L

20-229 b

TROUBLESHOOTING
12
MONITOR

CONNECTOR ARRANGEMENT DRAWING

PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT)

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

CONNECTOR ARRANGEMENT DRAWING

CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT)

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

CONNECTOR ARRANGEMENT DRAWING

CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)

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

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS


The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.

No.of pins

Male (female housing)


Part No.: 08055-00181

X type connector
Female (male housing)
Part No.: 08055-00191

799-601-7020

Part No.: 08055-00282

Part No.: 08055-00292

799-601-7030

Part No.: 08055-00381

Part No.: 08055-00391

---

---

T-adapter Part No.


799-601-7010

799-601-7040

Part No.: 08055-00481


Terminal part No.: 79A-222-3370
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.: 79A-222-3380
Electric wire size: 2.0
Grommet: Red
Qty: 20

PC400LC-7L

Part No.: 08055-00491


Terminal part No.: 79A-222-3390
Electric wire size: 0.85
Grommet: Black
Qty : 20
Terminal part No.: 79A-222-3410
Electric wire size: 2.0
Grommet: Red
Qty: 20

---

---

20-233 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

No.of
pins

SWP type connector


Male (female housing)

Female (male housing)

799-601-7050

Part No.: 08055-10681

Part No.: 08055-10691

799-601-7060

Part No.: 08055-10881

Part No.: 08055-10891

12

799-601-7310

Part No.: 08055-11281

Part No.: 08055-11291

14

799-601-7070

Part No.: 08055-11481

20-234 b

T-adapter
Part No.

Part No.: 08055-11491

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

SWP type connector


No.of pins

Male (female housing)

Female (male housing)

16

---

---

T-adapter
Part No.

799-601-7320

Part No.: 08055-11681


Terminal part No.:
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.:
Electric wire size: 1.25
Grommet: Red
Qty: 20

PC400LC-7L

Part No.: 08055-11691


Terminal part No.:
Electric wire size: 0.85
Grommet: Black
Qty: 20
Terminal part No.:
Electric wire size: 1.25
Grommet: Red
Qty: 20

---

---

20-235 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins
1

Male (female housing)


Part No.: 08056-00171

M type connector
Female (male housing)
Part No.: 08056-00181

799-601-7090

Part No.: 08056-00271

Part No.: 08056-00281

799-601-7110

Part No.: 08056-00371

Part No.: 08056-00381

799-601-7120

Part No.: 08056-00471

Part No.: 08056-00481

799-601-7130

Part No.: 08056-00671

Part No.: 08056-00681

799-601-7340

Part No.: 08056-00871

20-236 b

T-adapter Part No.


799-601-7080

Part No.: 08056-00881

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

S type connector
Female (male housing)

799-601-7140

Part No.: 08056-10871

Part No.: 08056-10881

10
(White)

799-601-7150

Part No.: 08056-11071

Part No.: 08056-11081

12
(White)

799-601-7350

Part No.: 08056-11271

Part No.: 08056-11281

16
(White)

799-601-7330

Part No.: 08056-11671

PC400LC-7L

T-adapter Part No.

Part No.: 08056-11681

20-237 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

S type connector
Female (male housing)

10
(Blue)

---

---

---

12
(Blue)

799-601-7160

Part No.: 08056-11272

Part No.: 08056-11282

16
(Blue)

799-601-7170

Part No.: 08056-11672

20-238 b

T-adapter Part No.

Part No.: 08056-11682

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins
7
11

Male (female housing)


Body part No.: 79A-222-2640 (Qty: 5)
Body part No.: 79A-222-2680 (Qty: 5)

MIC type connector


Female (male housing)
Body part No.: 79A-222-2630 (Qty: 5)
Body part No.: 79A-222-2670 (Qty: 5)

T-adapter Part No.


-----

799-601-2710

Body part No.: 79A-222-2620 (Qty: 5)

Body part No.: 79A-222-2610 (Qty: 5)

799-601-2950

Body part No.: 79A-222-2660 (Qty: 5)

Body part No.: 79A-222-2650 (Qty: 5)

13

799-601-2720

Body part No.: 79A-222-2710 (Qty: 2)

PC400LC-7L

Body part No.: 79A-222-2690 (Qty: 2)

20-239 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12

No.of
pins

Male (female housing)

MIC type connector


Female (male housing)

17

T-adapter Part No.

799-601-2730

Body part No.: 79A-222-2730 (Qty: 2)

Body part No.: 79A-222-2720 (Qty: 2)

21

799-601-2740

Body part No.: 79A-222-2750 (Qty: 2)


Terminal part No.: 79A-222-2770 (Qty: 50)

20-240 b

Body part No.: 79A-222-2740 (Qty: 2)


Terminal part No.: 79A-222-2760 (Qty: 50)

---

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

AMP040 type connector


Female (male housing)

T-adapter Part No.

799-601-7180

---

Housing part No.: 79A-222-3430 (Qty: 5)

12

799-601-7190

---

Housing part No.: 79A-222-3440 (Qty: 5)

16

799-601-7210

---

Housing part No.: 79A-222-3450 (Qty: 5)

20

799-601-7220

---

Housing part No.: 79A-222-3460 (Qty: 5)

Terminal part No.: 79A-222-3470 (No relation with number of pins)

PC400LC-7L

20-241 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

AMP070 type connector


Female (male housing)

10

799-601-7510

---

Part No.: 08195-10210

12

799-601-7520

---

Part No.: 08195-12210

14

799-601-7530

---

Part No.: 08195-14210

18

799-601-7540

---

Part No.: 08195-18210

20

799-601-7550

---

20-242 b

T-adapter Part No.

Part No.: 08195-20210

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

L type connector
Female (male housing)

---

---

No.of
pins

Male (female housing)

---

Connector for PA
Female (male housing)

---

Bendix MS connector
Male (female housing)

Female (male housing)

10

T-adapter Part
No.

799-601-3460

---

PC400LC-7L

T-adapter Part No.

---

---

No.of
pins

T-adapter Part No.

---

20-243 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

KES 1 (Automobile) connector


Female (male housing)

---

Part No.: 08027-10210 (Natural color)


08027-10220 (Black)

Part No.: 08027-10260 (Natural color)


08027-10270 (Black)

---

Part No.:08027-10310

Part No.:08027-10360

---

Part No.: 08027-10410 (Natural color)


08027-10420 (Black)

Part No.: 08027-10460 (Natural color)


08027-10470 (Black)

---

Part No.: 08027-10610 (Natural color)


08027-10620 (Black)

20-244 b

T-adapter Part No.

Part No.: 08027-10660 (Natural color)


08027-10670 (Black)

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
No.of
pins

Male (female housing)

KES 1 (Automobile) connector


Female (male housing)

T-adapter Part No.

---

Part No.: 08027-10810 (Natural color)


08027-10820 (Black)

No.of
pins

Male (female housing)

Part No.: 08027-10860 (Natural color)


08027-10870 (Black)

Connector for relay (Socket type)


Female (male housing)

799-601-7360

---

---

799-601-7370

---

No.of
pins

Male (female housing)

---

F type connector
Female (male housing)

T-adapter Part No.

---

---

PC400LC-7L

T-adapter Part No.

---

20-245 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part No.

799-601-9210

18-8 (1)

Part No.: 08191-11201, 08191-11202,


08191-11205, 08191-11206
Pin (female terminal)

Part No.: 08191-14101, 08191-14102,


08191-14105, 08191-14106
Pin (male terminal)

799-601-9210

Part No.: 08191-12201, 08191-12202,


08191-12205, 08191-12206
Pin (male terminal)

Part No.: 08191-13101, 08191-13102,


08191-13105, 08191-13106
Pin (female terminal)

799-601-9220

18-14
(2)

Part No.: 08191-21201, 08191-12202,


08191-21205, 08191-12206
Pin (female terminal)

Part No.: 08191-24101, 08191-24102,


08191-24105, 08191-24106
Pin (male terminal)

799-601-9220

Part No.: 08191-22201, 08191-22202,


08191-22205, 08191-22206

20-246 b

Part No.: 08191-23101, 08191-23102,


08191-23105, 08191-23106

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part No.

799-601-9230

Part No.:08191-31201, 08191-31202


Pin (female terminal)

Part No.:08191-34101, 08191-34102


Pin (male terminal)

18-20
(3)

799-601-9230

Part No.:08191-32201, 08191-32202


Pin (male terminal)

Part No.:08191-33101, 08191-33102


Pin (female terminal)

799-601-9240

Part No.:08191-41201, 08191-42202


Pin (female terminal)

Part No.:08191-44101, 08191-44102


Pin (male terminal)

18-21
(4)

799-601-9240

Part No.:08191-42201, 08191-42202

PC400LC-7L

Part No.:08191-43101, 08191-43102

20-247 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part No.

799-601-9250

24-9
(5)

Part No.:08191-51201, 08191-51202


Pin (female terminal)

Part No.:08191-54101, 08191-54102


Pin (male terminal)

799-601-9250

Part No.:08191-52201, 08191-52202


Pin (male terminal)

Part No.:08191-53101, 08191-53102


Pin (female terminal)

799-601-9260

24-16
(6)

Part No.: 08191-61201, 08191-62202,


08191-61205, 08191-62206
Pin (female terminal)

Part No.: 08191-64101, 08191-64102,


08191-64105, 08191-64106
Pin (male terminal)

799-601-9260

Part No.: 08191-62201, 08191-62202,


08191-62205, 08191-62206

20-248 b

Part No.: 08191-63101, 08191-63102,


08191-63105, 08191-63106

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter
Part No.

799-601-9270

24-21
(7)

Part No.: 08191-71201, 08191-71202,


08191-71205, 08191-71206
Pin (female terminal)

Part No.: 08191-74101, 08191-74102,


08191-74105, 08191-74106
Pin (male terminal)

799-601-9270

Part No.: 08191-72201, 08191-72202,


08191-72205, 08191-72206
Pin (male terminal)

Part No.: 08191-73101, 08191-73102,


08191-73105, 08191-73106
Pin (female terminal)

799-601-9280

24-22
(8)

Part No.: 08191-81201, 08191-81202


08191-81203, 08191-81204
08191-81205, 08191-80206
Pin (female terminal)

Part No.: 08191-84101, 08191-84102


08191-84103, 08191-84104
08191-84105, 08191-84106
Pin (male terminal)

799-601-9280

Part No.: 08191-82201, 08191-82202


08191-82203, 08191-82204
08191-82205, 08191-82206

PC400LC-7L

Part No.: 08191-83101, 08191-83102


08191-83103, 08191-83104
08191-83105, 08191-83106

20-249 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

12
Remark
The pin No. is also marked on the connector (electric wire insertion end).
Type
(shell
size
code)

HD30 Series connector


Body (plug)

Body (receptacle)

Pin (male terminal)

Pin (female terminal)

T-adapter Part No.

799-601-9290

24-31
(9)

Part No.: 08191-91203, 08191-91204,


08191-91205, 08191-91206
Pin (female terminal)

Part No.: 08191-94103, 08191-94104,


08191-94105, 08191-94106
Pin (male terminal)

799-601-9290

Part No.: 08191-92203, 08191-92204,


08191-92205, 08191-92206

20-250 b

Part No.: 08191-93103, 08191-93104,


08191-93105, 08191-93106

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

Part No.: 08192-12200 (normal type)


08192-22200 (fine wire type)

Part No.: 08192-12100 (normal type)


08192-22100 (fine wire type)

799-601-9030

Part No.: 08192-13200 (normal type)


08192-23200 (fine wire type)

Part No.: 08192-13100 (normal type)


08192-23100 (fine wire type)

799-601-9040

Part No.: 08192-14200 (normal type)


08192-24200 (fine wire type)

Part No.: 08192-14100 (normal type)


08192-24100 (fine wire type)

799-601-9050

Part No.: 08192-16200 (normal type)


08192-26200 (fine wire type)

PC400LC-7L

Part No.: 08192-16100 (normal type)


08192-26100 (fine wire type)

20-251 b

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

Part No.: 08192-1820 (normal type)


08192-2820 (fine wire type)

Part No.: 08192-1810 (normal type)


08192-2810 (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
12G: 799-601-9130
12BR: 799-601-9140

12

Part No.: 08192-1920 (normal type)


08192-2920 (fine wire type)

20-252 b

T-adapter Part No.

Part No.: 08192-1910 (normal type)


08192-2910 (fine wire type)

PC400LC-7L

TROUBLESHOOTING

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

Part No.: 08192-02200

No.of
pins

Body (plug)

Part No.: 08192-02100

DTHD Series connector


Body (receptacle)

T-adapter Part No.

---

Part No.: 08192-31200 (Contact size#12)


08192-41200 (Contact size #8)
08192-51200 (Contact size #4)

PC400LC-7L

Part No.: 08192-31100 (Contact size#12)


08192-41100 (Contact size #8)
08192-51100 (Contact size #4)

20-253 b

TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH TABLE

12

T-BRANCH BOX AND T-BRANCH TABLE

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.

Connector type or part name

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

T-BRANCH BOX AND T-BRANCH TABLE

Part No.

Connector type or part name

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

T-BRANCH BOX AND T-BRANCH TABLE

Connector type or part


name

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.

Connector type or part


name

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

---

T-BRANCH BOX AND T-BRANCH TABLE


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

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

For NE, G sensor

2P

799-601-9420

For fuel, boost press.

3P

799-601-9430

PVC socket

2P

PC400LC-7L

O
O

20-257 b

TROUBLESHOOTING

CONNECTION TABLE OF FUSE BOX

12

CONNECTION TABLE OF FUSE BOX


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 and fusible link to see if
the power is supplied normally.
Type of power supply

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Constant power supply


(Fusible link: A35)

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

Destination of powerDestination of power


Pump controller (Controller power supply)
Swing holding brake solenoid
(When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)
Machine push-up solenoid
ATT return selector relay & solenoid
Starting motor cutout relay (For PPC lock)
PPC lock solenoid
Cigarette lighter
Windshield washer motor
Horn
(Spare)
Rotary lamp
Right front working lamp & boom working lamp
One-touch power maximizing switch (Input to pump controller input)
Radio
(Spare)
Air conditioner unit
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)
Radio (For backing up)
Monitor panel (For backing up)
Starting switch
Room lamp
(Spare)

PC400LC-7L

TROUBLESHOOTING ERROR CODES IN MONITOR


SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-307
USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308
E101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
ERROR IN DATA HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
E112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
E113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE . . . . . . . . . . . . . . . . . . . . . 20-314
E114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
SHORT OR OPEN IN WINDOW WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
E115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
ABNORMAL WIPER MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
E116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
ABNORMALITY IN PARKING WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
E117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
ENGINE CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-322
E118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
PUMP CONTROLLER S-NET COMMUNICATION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
E128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
MONITOR COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
E201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
E203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-330
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM . . . . . . . . . . . . . . . . . . . . 20-330
E204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
SHORT IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
E205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
SHORT IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
E206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
SHORT IN TRAVEL SPEED SHIFT SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-336
E211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
OPEN IN TRAVEL INTERLOCKING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-338
E213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
OPEN IN SWING HOLDING BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
E214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
OPEN IN MERGE/DIVIDE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
E215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
OPEN IN 2-STAGE RELIEF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
E216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
OPEN IN TRAVEL SPEED SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
E217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
ABNORMAL INPUT MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-348
E218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
OPEN IN S-NET COMMUNICATION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-350
E222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352

PC400LC-7L

20-301 1

TROUBLESHOOTING

TABLE OF CONTENTS

SHORT IN LS-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-352


E223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
OPEN IN LS-EPC SOLENOID SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354
E224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
E225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
E226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
ABNORMAL PRESSURE SENSOR POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
E227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
E228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
SHORT IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
E232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
SHORT IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
E233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
OPEN IN PC-EPC SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
E238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
OPEN IN ATTACHMENT RETURN SWITCHING RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
E245 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . 20-372
E246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 20-374
E247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-376
E248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378A
BNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
E257 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
ABNORMALITY IN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
E315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
SHORT IN BATTERY RELAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
E91B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
ENGNE NE SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
E91C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
ENGINE G SENSOR PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
E920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
ENGINE TYPE SELECTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
E921 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
ENGINE TYPE MISMATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-390
E931 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
FUEL DIAL SYSTEM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
E934 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
ENGINE COOLANT SENSOR HI ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
E96A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
ENGINE COOLANT SENSOR LO ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
E936 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
ENGINE OIL PRESSURE SWITCH ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
E93C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
ENGINE BOOST SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
E93D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
ENGINE FUEL TEMPERATURE SENSOR ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
E953 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
ENGINE COMMUNICATION ABNORMALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404
E954 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
SHORT IN ENGINE IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
E955 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408
ENGINE S-NET ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-408

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

ENGINE WATER OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454


B@BCZK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
ENGINE WATER LEVEL LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
B@HANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
HYDRAULIC OIL OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458

20-304 1

PC400LC-7L

TROUBLESHOOTING
12

MEMORANDUM

PC400LC-7L

20-305 1

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM

12

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM


1.

Always turn power OFF before disconnecting or connecting connectors.

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.

When checking a single diode circuit:


Isolate the diode from the circuit.
using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
Electrical flow should be negative (-) to positive (+) only, red lead
positive and black lead negative.

6.

When checking a dual diode circuit:


Isolated the diode from the circuit.
using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
Electrical flow should be negative (-) to positive (+) only, red lead
positive and black lead negative.

7.

Always be aware of what you are measuring. Voltage, Ohms or Amps.


Always use caution when measuring a circuit.
When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are measuring.
When measuring ohms, be sure the circuit is dead and has no
voltage in it before you take any readings. Be sure the meter is set
in the proper ohms range.
When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage you equipment or possibly cause injury.
Always study the operators manuel for the meter you will be
using.

20-306 1

PC400LC-7L

TROUBLESHOOTING
12
POINTS

ITSELF

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM

TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY

There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1.

If any abnormality returns to normal by itself.

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.

USER CODE MEMORY RETENTION FUNCTION


When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase
the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed.
There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this
way saves any wasted work.

PC400LC-7L

20-307 1

TROUBLESHOOTING

INFORMATION CONTAINED IN TESTING PROCEDURES

12

INFORMATION CONTAINED IN TESTING PROCEDURES


The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.

Tools and Procedures

Contents Of Trouble

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while
performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Service Code

What you
testing

are

4.

No.

Readings

Resistance
or
Voltage

Test procedure for component only.

readings

Your
information

Test procedure for component only.

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

At a diode, between point (x) and (x) reverse meter lead


polarity each time to check diode.

Continuity one
way only?

Yes or No

Wiring harness assembly test

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

Test procedure for harness. (connector) to (connector)

readings

Your
information

Test procedure for harness. (connector) to (connector)

readings

Your
information

B.Short to chassis ground or


within harness

Resistance
or
Voltage

Test procedure for harness. (connector) to (connector)

readings

Your
information

Test procedure for harness. (connector) to (connector)

readings

Your
information

Additional components to be tested

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

Test procedure for any additional components.

readings

Your
information

PC400LC-7L

TROUBLESHOOTING

INFORMATION CONTAINED IN TESTING PROCEDURES

12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.

Connector No.: Indicates (Type - numbers of a pin) (color)


Arrow: Roughly indicates the location in the machine where it is installed.

PC400LC-7L

20-309 1

TROUBLESHOOTING

E101

12

E101
ERROR IN DATA HISTORY

Tools and Procedures

Contents Of Trouble

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E101]


Batteries

Fuse link and fuses


1.

Data chain error


Failure code DAF0KT displayed.
Can not access failure codes on monitor.

Specifications

No.

Readings

Check condition of batteries and connections before proceeding with these tests.

Good
Condition?

Yes or No

Check condition of fuse links A34(L-2) and


A35(M-2)
Check condition of fuses in fuse box FB1 12 (20A) and
17 (10A).

Good
Condition?

Yes or No

At fuse link A34, between (1) and (2)

0.0 to 1.0

At fuse link A35, between (1) and (2)

0.0 to 1.0

Good?

* At connector H10, between (1) and chassis ground

30 to 20V

* At connector H10, between (5) and chassis ground

30 to 20V

At connector H10, between (4) and chassis ground

0.0 to 1.0

At connector H10, between (1) and chassis ground

(OL) open

At connector H10, between (5) and chassis ground

(OL) open

10

At connector H10, between (4) and (5)

(OL) open

11

At connector H10, between (1) and (5)

(OL) open

12

Fuse link and fuses (FB1)

With ignition switch in the OFF position.

Disconnect A34 and A35 fuse link connectors.

Zero meter leads for proper readings.


A.

Fuse tests

Resistance

Check condition of fuses at (FB1)


2.

A.

B.

3.

Yes or No

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect H10 connector from monitor panel.

* Turn ignition switch to the ON position for these tests only.


Open or high
resistance
Short
to
chassis
ground or within harness

Voltage
Resistance

Resistance

Monitor panel test

With ignition in the OFF position.

Disconnect P01 connector from monitor panel and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

Voltage
Resistance

20-310 1

Between P01, (1) (2) and chassis ground

30 to 20V

Between P01, (8) and chassis ground

30 to 20V

13
14

Between P01, (6) (7) and chassis ground

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

Tools and Procedures

Contents Of Trouble

Possible short or open in wiper motor drive system.


Failure code DY2DBK.
No wiper operation.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E112]

A.

Wiper motor

Voltage
Resistance

2.

No.

Readings

* At connector W04, between (1) and (3), wiper switch


20 to 30V cycling
set ON.

At connector W04, (1) and chassis ground.

(OL) open

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect W04 connector from wiper motor.

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

With ignition switch in the OFF position.

Disconnect W04 connector from motor and install T-adapter between motor and connector W04.

* Turn ignition switch to the ON position for this test.

Open or high
resistance

Short to chassis
ground or within
harness

Resistance

Resistance

Between connectors W04, (1) and P01, (10)

0.0 to 1.0

Between connectors W04, (3) and P01, (9)

0.0 to 1.0

Between connectors W04, (4) and P01, (12)

0.0 to 1.0

Between connectors W04, (5) and chassis ground

0.0 to 1.0

Between connectors W04, (6) and P01, (5)

0.0 to 1.0

Between connectors W04, (5) and P02, (15)

0.0 to 1.0

At connector W04, (1) and chassis ground

(OL) open

At connector W04, (3) and chassis ground

(OL) open

10

At connector W04, (4) and chassis ground

(OL) open

11

At connector W04, (5) and chassis ground

(OL) open

12

At connector W04, (6) and chassis ground

(OL) open

13

At connector W04, (1) and (3) (4) (5) (6)

(OL) open

14

At connector W04, (4) and (5) (6)

(OL) open

15

At connector W04, (5) and (6)

(OL) open

16

At connector P02 (15) and W03 (2)

(OL) open

17

At connector W04 (5) and W03 (1)

(OL) open

18

Monitor panel test

With ignition switch in the OFF position.

Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

20-312 1

Voltage

Between P01, (9) and chassis ground, wiper ON

20 to 30V cycling

19

Between P01, (9) and chassis ground, wiper OFF

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

Tools and Procedures

Contents Of Trouble

Possible short or open in wiper motor drive system.


Failure code DY2EKB.
No wiper operation.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E113]

A.

Wiper motor

Voltage
Resistance

2.

No.

Readings

* At connector W04, between (1) and (3), wiper switch


20 to 30V cycling
set ON.

At connector W04, (1) and chassis ground.

(OL) open

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect W04 connector from wiper motor.

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

With ignition switch in the OFF position.

Disconnect W04 connector from motor and install T-adapter between motor and connector W04.

* Turn ignition switch to the ON position for this test.

Open or high
resistance

Short to chassis
ground or within
harness

Resistance

Resistance

Between connectors W04, (1) and P01, (10)

0.0 to 1.0

Between connectors W04, (3) and P01, (9)

0.0 to 1.0

Between connectors W04, (4) and P01, (12)

0.0 to 1.0

Between connectors W04, (5) and chassis ground

0.0 to 1.0

Between connectors W04, (6) and P01, (5)

0.0 to 1.0

Between connectors W04, (5) and P02, (15)

0.0 to 1.0

At connector W04, (1) and chassis ground

(OL) open

At connector W04, (3) and chassis ground

(OL) open

10

At connector W04, (4) and chassis ground

(OL) open

11

At connector W04, (5) and chassis ground

(OL) open

12

At connector W04, (6) and chassis ground

(OL) open

13

At connector W04, (1) and (3) (4) (5) (6)

(OL) open

14

At connector W04, (4) and (5) (6)

(OL) open

15

At connector W04, (5) and (6)

(OL) open

16

At connector P02 (15) and W03 (2)

(OL) open

17

At connector W04 (5) and W03 (1)

(OL) open

18

Monitor panel test

With ignition switch in the OFF position.

Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

20-314 1

Voltage

Between P01, (9) and chassis ground, wiper ON

20 to 30V cycling

19

Between P01, (9) and chassis ground, wiper OFF

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

Tools and Procedures

Contents Of Trouble

Circuit Diagnostic Procedures For Code [E114]

B.

Readings

Washer motor

Voltage

* At connector A05, between (13) and (14), washer


switch set ON.

20 to 30V

At connector A05, between (13) and (14), washer switch


set OFF.

0V

Open or high
resistance
Short to chassis
ground or within
harness

Voltage
Resistance
Resistance

* Between connector A05, (13) and chassis ground

20 to 30V

Between connectors A05, (14) and P01, (3)

0.0 to 1.0

At connector A05, (13) and chassis ground

(OL) open

At connector A05, (14) and chassis ground

(OL) open

Continuity one
way only?

Diode test

With ignition switch in the OFF position.

Disconnect D04 diode connector and isolate diode


A.

4.

No.

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect A05 connector from washer motor.

Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.

* Turn ignition switch to the ON position for this test.


A.

3.

Specifications

Washer motor

With ignition switch in the OFF position.

Disconnect A05 connector from motor and install T-adapter between motor and connector A05.

* Turn ignition switch to the ON position for this test.


A.

2.

Possible short or open in wiper motor drive system.


Failure code DY2CKB.
No wiper operation.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Diode test

Resistance

At diode D04, between (4) and (8) reversing meter lead


polarity each time to check.

Yes or No

Monitor panel test

With ignition switch in the OFF position.

Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

20-316 1

Voltage

Between P01, (3) and chassis ground, washer OFF

20 to 30V

Between P01, (3) and chassis ground, washer ON

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

Tools and Procedures

Contents Of Trouble

Circuit Diagnostic Procedures For Code [E115]

No.

Readings

Wiper motor

Resistance

At connector W04, between (6) and (5), wiper at far end


of operation.

0.0 to 1.0

At connector W04, between (6) and (5), wiper at mid


point on windshield.

(OL) open

Between W04, (1) and P01, (10)

0.0 to 1.0

Between W04, (3) and P01, (9)

0.0 to 1.0

Between W04, (4) and P01, (12)

0.0 to 1.0

Between W04, (5) and chassis ground

0.0 to 1.0

Between W04, (6) and P01, (5)

0.0 to 1.0

Between P02, (15) and chassis ground

0.0 to 1.0

At connector W04, (1) and chassis ground

(OL) open

At connector W04, (3) and chassis ground

(OL) open

10

At connector W04, (4) and chassis ground

(OL) open

11

At connector W04, (6) and chassis ground

(OL) open

12

At connector W04, (1) and (3) (4) (5) (6)

(OL) open

13

At connector W04, (3) and (4) (5) (6)

(OL) open

14

At connector W04, (4) and (5) (6)

(OL) open

15

At connector W04, (5) and (6)

(OL) open

16

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect W04 connector from wiper motor.

Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.

A.

B.

3.

Specifications

Wiper motor park system

With ignition switch in the OFF position.

Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
A.

2.

Abnormal wiper motor operation.


Failure code DY20KA.
No wiper operation.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Open or high
resistance

Short to chassis
ground or within
harness

Resistance

Resistance

Monitor panel test

With ignition switch in the OFF position.

Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

20-318 1

Voltage

Between P01, (5) and chassis ground, wiper end


Between P01, (5) and chassis ground, wiper at mid point

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

Tools and Procedures

Contents Of Trouble

Circuit Diagnostic Procedures For Code [E116]

No.

Readings

Wiper motor

Resistance

At connector W04, between (6) and (5), wiper at far end


of operation.

0.0 to 1.0

At connector W04, between (6) and (5), wiper at mid


point on windshield.

(OL) open

Between W04, (1) and P01, (10)

0.0 to 1.0

Between W04, (3) and P01, (9)

0.0 to 1.0

Between W04, (4) and P01, (12)

0.0 to 1.0

Between W04, (5) and chassis ground

0.0 to 1.0

Between W04, (6) and P01, (5)

0.0 to 1.0

Between P02, (15) and chassis ground

0.0 to 1.0

At connector W04, (1) and chassis ground

(OL) open

At connector W04, (3) and chassis ground

(OL) open

10

At connector W04, (4) and chassis ground

(OL) open

11

At connector W04, (6) and chassis ground

(OL) open

12

At connector W04, (1) and (3) (4) (5) (6)

(OL) open

13

At connector W04, (3) and (4) (5) (6)

(OL) open

14

At connector W04, (4) and (5) (6)

(OL) open

15

At connector W04, (5) and (6)

(OL) open

16

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect W04 connector from wiper motor.

Disconnect P01 connector from monitor panel and install T-adapter between P01 connector only.

A.

B.

3.

Specifications

Wiper motor park system

With ignition switch in the OFF position.

Disconnect W04 connector from motor and install T-adapter between motor and connector W04.
A.

2.

Abnormal in parking wiper motor arm.


Failure code DY20MA.
Wiper will not park.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Open or high
resistance

Short to chassis
ground or within
harness

Resistance

Resistance

Monitor panel test

With ignition switch in the OFF position.

Disconnect P01 connector from monitor and install T-adapter between P01 wiring harness connector and monitor panel.

Turn ignition switch to the ON position.


A.

Monitor panel

20-320 1

Voltage

Between P01, (12) and chassis ground, wiper parked


Between P01, (12) and chassis ground, wiper at mid point

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.

Response from monitor panel

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E117]

A.

B.

2.

Readings

Open or high
resistance

Resistance

Grounding fault
wiring harness
(Contact with
grounding circuit)

of
Resistance

Between pump controller C02 (21) and monitor panel P02


(9) or (10)

0.0 to 1.0

Between pump controller C02 (21) and engine controller


CB2 (21) and (31)

0.0 to 1.0

Between monitor panel P02 (20) and chassis ground

0.0 to 1.0

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31) and related circuits and
grounding

Above 1 M

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

Above 1 M

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31) and related circuits and
grounding

Short-circuit (Contact
with 24V circuit)

Voltage

0V

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

0V

CB2 (21) [S-NET (+)] and (11) [GND]

6 - 9V

CB2 (21) [S-NET (+)] and (11) [GND]

6 - 9V

Between P02 (9) [N/W signal] and (20) [N/W GND]

6 - 9V

10

Between P02 (10) [N/W signal] and (20) [N/W GND]

6 - 9V

11

Engine controller

Turn the engine ignition switch OFF for the preparations.

Disconnect CB2 connector and install T-adapter.

Hold ignition switch in the ON position during the troubleshooting.


A.

4.

No.

Wiring harness assembly test

With ignition switch in OFF position, make the test preparations.

During test hold ignition switch in the ON position.


A.

3.

Specifications

Wiring harness assembly test

With ignition switch in OFF position.

Defective
test

controller

Voltage

Monitor panel test

With ignition switch in the OFF position.

Disconnect P02 connector from monitor and install T-adapter.

Turn ignition switch to the ON position during the troubleshooting.


A.

Monitor panel test

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.

Response from monitor panel

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E118]

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

Between P02 (20) monitor panel and chassis ground

0.0 to 1.0

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31) and related circuits and
grounding

Above 1 M

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

Above 1 M

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31) and related circuits and
grounding

Short-circuit (Contact
with 24V circuit)

Voltage

0V

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

0V

6 - 9V

Between P02 (9) [N/W signal] and (20) [N/W GND]

6 - 9V

10

Between P02 (10) [N/W signal] and (20) [N/W GND]

6 - 9V

11

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C02 connector and install T-adapter.

Hold ignition switch in the ON position during the troubleshooting.


A.

4.

No.

Wiring harness assembly test

With ignition switch in OFF position, make the test preparations.

During test hold ignition switch in the ON position.


A.

3.

Specifications

Wiring harness assembly test

With ignition switch in OFF position.

Defective
test

controller

Voltage

C02 (21) S-NET and (31) S-NET GND

Monitor panel test

With ignition switch in the OFF position.

Disconnect P02 connector from monitor and install T-adapter.

Turn ignition switch to the ON position during the troubleshooting.


A.

Monitor panel test

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

Response from monitor panel

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

Relative information

---

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E128]

A.

No.

Open or high
resistance

Resistance

Between P70 (16) monitor panel and CB2 (22) engine


controller

0.0 to 1.0

Between P70 (16) monitor panel and C02 (22) pump


controller

0.0 to 1.0

Between P70 (15) monitor panel and CB2 (32) engine


controller

0.0 to 1.0

Between P70 (15) monitor panel and C02 (32) pump


controller

0.0 to 1.0

0.0 to 1.0

Between monitor panel P70 (16) and engine controller


CB2 (22)

Above 1 M

Between monitor panel P70 (16) and engine controller


C02 (22)

Above 1 M

Between monitor panel P70 (16) and related circuits and


grounding

Above 1 M

Between monitor panel P70 (15) and engine controller


CB2 (32)

Above 1 M

Between monitor panel P70 (15) and engine controller


C02 (32)

Above 1 M

10

Between monitor panel P70 (15) and related circuits and


grounding

Above 1 M

11

Between monitor panel P70 (16) and engine controller


CB2 (22)

0V

Between monitor panel P70 (16) and pump controller C02


(22)

0V

Between monitor panel P70 (16) and related circuits and


grounding

0V

Between monitor panel P70 (15) and engine controller


CB2 (32)

0V

Between monitor panel P70 (15) and pump controller C02


(32)

0V

10

Between monitor panel P70 (15) and related circuits and


grounding

0V

11

Between P70 (14) monitor panel and chassis ground

B.

2.

Specifications

Readings

Wiring harness assembly test

With ignition switch in OFF position.

Grounding fault
wiring harness
(Contact with
grounding circuit)

of
Resistance

Wiring harness assembly test

With ignition switch in OFF position, make the test preparations.

During test hold ignition switch in the ON position.

A.

Short-circuit (Contact
with 24V circuit)

20-326 1

Voltage

PC400LC-7L

TROUBLESHOOTING
Steps
3.

Circuit Diagnostic Procedures For Code [E128]

Specifications

No.

Readings

CAN terminal resistors

Turn the engine ignition switch OFF.

Hold the ignition switch in the OFF position for this test
A.

4.

E128

Defective CAN
resistor tests

Resistance

K30 between (A) and (B)

40 - 80

12

K31 between (A) and (B)

40 - 80

13

Monitor panel, engine controller or pump controller

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.)

Monitor Communication related to CAN communication

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

Tools and Procedures

When power was turned on, there was abnormal current supplied to the travel interlocking circuit.
Failure code DW91KB.

Power supply to the travel interlocking circuit is switched OFF.


Even if the failure cause disappears of itself, the solenoid circuit does not return to normal, unless the engine starting
switch is turned OFF.

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)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E201]

A.
2.

No.

Readings

Resistance

Solenoid test

At solenoid V02, between (1) and (2)

20 to 60

At solenoid V02, between (1) and chassis ground

(OL) open

Above 1M

C03 (7) and ground - Levers - Neutral position

0V

C03 (7) and ground - Levers - Steering actuated

20 - 30V

Wiring harness assembly test

With ignition switch in OFF position, make the test preparations.

Hold ignition switch in OFF position during troubleshooting.


A.

3.

Specifications

Solenoid test

With ignition switch in the OFF position.

Disconnect V02 connector from solenoid.

Zero meter leads for proper readings.

Ground
fault
test
(Contact with
grounding circuit)

Resistance

Between pump controller C03 (7) to travel junction


solenoid V02 (2) connection and ground

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C02 connector and install T-adapter.

Ignition switch in the ON position, engine running during the troubleshooting.

Move RH & LH travel control levers


A.

Defective
test

controller

Voltage

Travel interlocking solenoid circuit diagram

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

Tools and Procedures

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.)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E203]

A.

2.

Readings

Swing holding brake


solenoid test (Internal
short or ground fault)

At solenoid V05, between (1) and (2)


Resistance

At solenoid V05, between (2) and ground

20 to 60

Above 1M

Resistance

Diode test

At diode D01, between (3) and (7) reversing meter lead


polarity each time to check.

Continuity one
way only?

Wiring harness assembly test

With ignition switch in OFF position.

Disconnect V05 connector from solenoid.

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.

Hold ignition switch in OFF position during troubleshooting.

A.

B.

4.

No.

Diode test

With ignition switch in the OFF position.

Disconnect D01 diode connector and isolate.


A.

3.

Specifications

Solenoid test

With ignition switch in the OFF position.

Disconnect V05 connector from solenoid.

Zero meter leads for proper readings.

Open or high
resistance

Resistance

Short
to
chassis
ground or within
harness

Resistance

Between connectors C03 (37) and S25 (8)

Above 1M

Between connectors C03 (37) and X05 (3)

Above 1M

Between connectors C02 (2) and S25 (9)

Above 1M

Between connectors V05 (2) and X05 (4)

Above 1M

Between connectors V05 (1) and S25 (8)

Above 1M

Between connectors V05 (1) and chassis ground

Above 1M

At connectors V05 (2) and chassis ground

(OL) open

10

At connector V05 between (1) and (2)

(OL) open

11

C03 (37) and ground - Levers - Neutral position

0V

12

C03 (37) and ground - Levers - Steering actuated

20 - 30V

13

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Ignition switch in the ON position, engine running during the troubleshooting.

Move RH & LH travel control levers


A.

Defective
test

20-330 1

controller

Voltage

PC400LC-7L

TROUBLESHOOTING

E203

Electrical Circuit Diagram for Swing Holding Brake Solenoid

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

Tools and Procedures

Short in merge/divide solenoid circuit (Pump controller system).


Failure code DWJ0KB.

Power supply to the merge/divide 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.

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)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E204]

A.

2.

3.

Specifications

No.

Readings

Solenoid test

With ignition switch in the OFF position.

Disconnect V05 connector from solenoid.

Zero meter leads for proper readings.


Swing holding brake
solenoid test (Internal
short or ground fault)

At solenoid V03, between (1) and (2)


Resistance

At solenoid V03, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

With ignition switch in OFF position.

Disconnect V03 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

B.

Short
to
chassis
ground or within
harness

Resistance

Between connectors C03 (17) and V01 (2)

Above 1M

At connector V02, between (1) and chassis ground

(OL) open

At connector V02, between (1) and (2)

(OL) open

0V

20 - 30V

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Ignition switch in the ON position, engine running during the troubleshooting.

Move RH & LH travel control levers


A.

Defective
test

20-332 1

controller

Voltage

C03 (17) and ground - Levers - Neutral position


C03 (17) and ground - Levers - operating one side only

PC400LC-7L

TROUBLESHOOTING

E204

Electrical Circuit Diagram for Merge/Divide Solenoid

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

Tools and Procedures

Short in 2-stage relief solenoid circuit (Pump controller system).


Failure code DWK0KB.

Power supply to the 2-stage relief 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.

The one-touch power max. switch does not work.


(The main relief valve cannot be set to high-pressure set.)

Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E205]

A.

2.

3.

Specifications

No.

Readings

Solenoid test

With ignition switch in the OFF position.

Disconnect V08 connector from solenoid.

Zero meter leads for proper readings.


Swing holding brake
solenoid test (Internal
short or ground fault)

At solenoid V08, between (1) and (2)


Resistance

At solenoid V08, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

With ignition switch in OFF position.

Disconnect V03 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter on C03 wiring harness connector only.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

B.

Short
to
chassis
ground or within
harness

Resistance

Between connectors C03 (28) and V08 (2)

Above 1M

At connector V08, between (1) and chassis ground

(OL) open

At connector V02, between (1) and (2)

(OL) open

0V

20 - 30V

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Turn ignition switch ON.


A.

Defective
test

20-334 1

controller

Voltage

C03 (28) and ground - Other than L mode


C03 (28) and ground - L mode

PC400LC-7L

TROUBLESHOOTING

E205

Electric Circuit Diagram for 2-stage Relief Solenoid

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

Tools and Procedures

Short in travel speed shifting solenoid circuit (Pump controller system).


Failure code DW43KB.

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.

The travel speed does not turn to HI.


(The travel motor swash plate angle does not turn to minimum.)

Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E206]

A.

2.

3.

Specifications

No.

Readings

Solenoid test

With ignition switch in the OFF position.

Disconnect V04 connector from solenoid.

Zero meter leads for proper readings.


Travel speed shifting
solenoid test (Internal
short or ground fault)

20 to 60

Above 1M

Above 1M

At connector V04, between (1) and chassis ground

(OL) open

At connector V02, between (1) and (2)

(OL) open

C03 (27) and ground - travel speed Lo + travel lever


Neutral

0V

C03 (27) and ground - travel speed Hi + travel lever


in operation

20 - 30V

At solenoid V04, between (1) and (2)


Resistance

At solenoid V04, between (1) and ground

Wiring harness assembly test

With ignition switch in OFF position.

Disconnect V04 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

B.

Short
to
chassis
ground or within
harness

Resistance

Between connectors C03 (27) and V04 (2)

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Turn ignition switch ON.


A.

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.

Response from controller

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.

It is difficult to steer the machine while traveling.


(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)
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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E211]

A.

2.

3.

Specifications

No.

Readings

Solenoid test

With ignition switch in the OFF position.

Disconnect V02 connector from solenoid.

Zero meter leads for proper readings.


Travel speed shifting
solenoid test (Internal
short or ground fault)

At solenoid V02, between (1) and (2)


Resistance

At solenoid V02, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

With ignition switch in OFF position.

Disconnect V04 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

Between connectors C03 (7) and V02 (2)

Below 1

B.

Short
to
chassis
ground or within
harness

Resistance

Between C03 (3), (13), (23) and V02 (1)

Below 1

20 - 60

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Hold ignition in the OFF position.


A.

Defective
test

20-338 1

controller

Voltage

Between C03 (7) and (3), (13), (23)

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E203]

A.

2.

Specifications

No.

Readings

Solenoid test

With ignition switch in the OFF position.

Disconnect V05 connector from solenoid.

Zero meter leads for proper readings.


Swing holding brake
solenoid test (Internal
short or ground fault)

At solenoid V05, between (1) and (2)


Resistance

At solenoid V05, between (2) and ground

20 to 60

Above 1M

Swing lock switch test

With ignition switch in OFF position.

Disconnect X05 connector and install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


Swing lock switch
A.

3.

Resistance

Between X05 (3) and (4)

OFF

Below 1

ON

Above 1M

Continuity one
way only?

Diode test

With ignition switch in the OFF position.

Disconnect D01 diode connector and isolate.


A.

4.

Swing lock switch test

Diode test

Resistance

At diode D01, between (3) and (7) reversing meter lead


polarity each time to check.

Wiring harness assembly test

Disconnection or defective contact with connector.

With ignition switch in OFF position.

Disconnect V05 connector from solenoid.

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.

Hold ignition switch in OFF position during troubleshooting.


A.

B.

Open or high
resistance

Resistance

Between connectors C03 (37) and D01 (7)

Below 1

Between connectors D01 (3) to J02 to X05 (3)

Below 1

Between connectors X05 (4) to V05 (2)

Below 1

Between connectors C03 (3), (13), (23) and V05(1)

Below 1

Short between wires or ground


With ignition switch in OFF position for preparation.
Hold ignition switch in ON position during trouble shooting.

20-340 1

PC400LC-7L

TROUBLESHOOTING
Steps

Circuit Diagnostic Procedures For Code [E203]

--5.

E213

---

Voltage

At connectors C03 (37) and D01 (7) and ground

Specifications

No.

Below 1V

10

20 - 60

11

Readings

Pump controller

With ignition switch in OFF position.

Disconnect C03 connector from controller and install T-adapter on C03connector.

Disconnect D01 and connect pins (3) and (7) of female side for test.

Hold ignition switch in OFF position during troubleshooting.


A.

Defective pump
controller test

Resistance

At C03 (17) and between pins (3), (13), (23)

Electrical Circuit Diagram for Swing Holding Brake Solenoid

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E214]

A.

2.

3.

No.

Readings

Merge/divide solenoid
test (Internal short or
ground fault)

At solenoid V02, between (1) and (2)


Resistance

At solenoid V02, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

Checking for disconnection or defective contact with connector.

With ignition switch in OFF position.

Disconnect V02 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

Between connectors C03 (17) and V03 (2)

Below 1

B.

Short
to
chassis
ground or within
harness

Resistance

Between C03 (3), (13), (23) and V03 (1)

Below 1

Below 1V

20 - 60

Short in wiring harness (Contact with 24V circuit).

With ignition switch in OFF position.

Hold ignition switch in ON position during troubleshooting.


A.

4.

Specifications

Solenoid test

With ignition switch in the OFF position.

Disconnect V03 connector from solenoid.

Zero meter leads for proper readings.

Short & contact with


24V circuit

Voltage

Check wiring harness from C03 (17) to V03 (2) and


grounding

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Hold ignition in the OFF position.


A.

Defective
test

20-342 1

controller

Resistance

Between C03 (17) and (3), (13), (23)

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.

Response from controller

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.

The one-touch power max. switch does not work.


(The main relief valve cannot be set to high-pressure set.)

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E215]

A.

2.

3.

No.

Readings

2-stage relief solenoid


test (Internal short or
ground fault)

At solenoid V08, between (1) and (2)


Resistance

At solenoid V08, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

Checking for disconnection or defective contact with connector.

With ignition switch in OFF position.

Disconnect V08 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

Between connectors C03 (28) and V08 (2)

Below 1

B.

Short
to
chassis
ground or within
harness

Resistance

Between C03 (3), (13), (23) and V08 (1)

Below 1

Below 1V

20 - 60

Short in wiring harness (Contact with 24V circuit).

With ignition switch in OFF position.

Hold ignition switch in ON position during troubleshooting.


A.

4.

Specifications

Solenoid test

With ignition switch in the OFF position.

Disconnect V08 connector from solenoid.

Zero meter leads for proper readings.

Short & contact with


24V circuit

Voltage

Check wiring harness from C03 (28) to V08 (2) and


grounding

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Hold ignition in the OFF position.


A.

Defective
test

20-344 1

controller

Resistance

Between C03 (28) and (3), (13), (23)

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.

Response from controller

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.

The travel speed does not shift to Hi.


(The travel motor swash plate angle does not turn to minimum.)

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E216]

A.

2.

3.

No.

Readings

Travel speed solenoid


test (Internal short or
ground fault)

At solenoid V04, between (1) and (2)


Resistance

At solenoid V04, between (1) and ground

20 to 60

Above 1M

Wiring harness assembly test

Checking for disconnection or defective contact with connector.

With ignition switch in OFF position.

Disconnect V04 connector from solenoid.

Disconnect C03 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.


A.

Open or high
resistance

Resistance

Between connectors C03 (27) and V04 (2)

Below 1

B.

Short
to
chassis
ground or within
harness

Resistance

Between C03 (3), (13), (23) and V04 (1)

Below 1

Below 1V

20 - 60

Short in wiring harness (Contact with 24V circuit).

With ignition switch in OFF position.

Hold ignition switch in ON position during troubleshooting.


A.

4.

Specifications

Solenoid test

With ignition switch in the OFF position.

Disconnect V04 connector from solenoid.

Zero meter leads for proper readings.

Short & contact with


24V circuit

Voltage

Check wiring harness from C03 (27) to V04 (2) and


grounding

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C03 connector and install T-adapter.

Hold ignition in the OFF position.


A.

Defective
test

20-346 1

controller

Resistance

Between C03 (27) and (3), (13), (23)

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

Tools and Procedures

A model code signal for a model which is not registered in the controller is inputted. (Pump controller system).
Failure code DA2SKQ.

The controller controls the machine as a default model (PC750).


Even after the failure cause disappears of itself, the machine operation does not return to normal, unless the engine
starting switch is turned OFF.

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.)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E217]

A.

2.

Specifications

No.

Readings

Model selection connector

With ignition switch in the OFF position.

Disconnect C09 connector and use T-adapter.

Hold ignition switch in OFF position for troubleshooting.


Model selection
connector test (Internal
short or ground fault)

At C09, between (4), (5), (6), (8)


Resistance

At C09, between (1), (2), (3), (7), (8)

in. 1M

ax. 1

Wiring harness assembly test

Checking for disconnection or defective contact with connector.

With ignition switch in OFF position.

Disconnect C02 connector from governor pump controller an install T-adapter.

Hold ignition switch in OFF position during troubleshooting.

A.

Open or high
resistance

Resistance

C02 (37) and C09 (1)

ax. 1

C02 (27) and C09 (2)

ax. 1

C02 (17) and C09 (3)

ax. 1

C02 (13) and C09 (7)

ax. 1

C09 (8), J05, and ground (A13)

ax. 1

in. 1M

3.

Short in wiring harness.

With ignition switch in OFF position.

Hold ignition switch in OFF position during troubleshooting.

4.

Pump controller

Turn the engine ignition switch OFF for the preparations.

Disconnect C02 connector and install T-adapter.

Hold ignition in the ON position during troubleshooting.

A.

A.

Short & contact

Defective
test

20-348 1

controller

Resistance

Voltage

Check wiring harness from C02 (7) to C09 (4) and ground

Between C02 (7) and ground

5 - 30V

Between C02 (37), (27), (17), (13) and ground

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.

Response from controller

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E218]

A.

B.

2.

Specifications

No.

Readings

Wiring harness assembly test

With ignition switch in OFF position.

Hold in the OFF position during troubleshooting.

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

Between P02 (20) monitor panel and chassis ground

Max. 1

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31)

Min. 1M

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

Min. 1M

Between monitor panel P02 (9), (10) related circuits and


grounding

Min. 1M

Between monitor panel P02 (9), (10) and engine


controller CB2 (21), (31) and related circuits and
grounding

Max. 1V

Between monitor panel P02 (9), (10) and pump controller


C02 (21) and related circuits and grounding

Max. 1V

Between monitor panel P02 (9), (10) related circuits and


grounding

Max. 1V

6 - 9V

10

6 - 9V

11

Wiring harness assembly test

With ignition switch in OFF position, make the test preparations.

During test hold ignition switch in the ON position.

A.

Short-circuit (Contact
with 24V circuit)

Voltage

3.

Monitor panel test

With ignition switch in the OFF position.

Disconnect P02 connector from monitor and install T-adapter.

Turn ignition switch to the ON position during the troubleshooting.

4.

Engine controller test

Turn the engine ignition switch OFF for the preparations.

Disconnect CB2 connector and install T-adapter.

Hold ignition switch in the ON position during the troubleshooting.

A.

A.

Monitor panel test

Defective
test

20-350 1

controller

Voltage

Voltage

Between P02 (9), (10) [N/W signal] and (20) [N/W GND]

CB2 (21), (31) and (11)

PC400LC-7L

TROUBLESHOOTING
Steps
5.

E218

Circuit Diagnostic Procedures For Code [E218]

Specifications

No.

Readings

Pump controller test

With ignition switch in the OFF position.

Disconnect C02 connector from monitor and install T-adapter.

Turn ignition switch to the ON position during the troubleshooting.


A.

Monitor panel test

Voltage

C02, between (21) and (31)

6 - 9V

12

Electrical Circuit Diagram for S-NET Communication

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

Tools and Procedures

Short in LS-EPC solenoid circuit.


Failure code DXE0KB.

The controller reduces the output to the LS-EPC solenoid circuit to 0.


Even if the failure cause disappears, the current does not return to normal, unless the engine ignition switch is turned
OFF.

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.)

Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.


(Code No.: 01500 LS-EPC solenoid current.)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E222]

A.

2.

3.

Specifications

No.

Readings

LS-EPC solenoid

Turn the engine ignition switch OFF for preparations

Disconnect V22 connection.

Hold ignition switch OFF during troubleshooting.


LS-EPC solenoid test
(internal
short
or
ground fault)

At connection V22, between (1) and (2)


Resistance

7 - 14

Above 1 M

Between C03 (6) and V22 (1) and ground

Above 1 M

At connector V22, between (1) and ground

(OL) open

At connector V22, between (2) and ground

(OL) open

At connector V22, between (1) and (2)

(OL) open

7 - 14

Above 1 M

At connection V22, Between (1) and ground

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.


A.

Open or high
resistance

B.

Grounding fault
wiring harness
(Contact with
grounding circuit)

Resistance
of
Resistance

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.


A.

Pump controller

20-352 1

Resistance

Between C03 (6) and (3), (13), (23)


Between C03 (6) and ground

PC400LC-7L

TROUBLESHOOTING

E222

Electrical Circuit Diagram for LS-EPC Solenoid

PC400LC-7L

20-353 1

TROUBLESHOOTING

E223

12

E223
OPEN IN LS-EPC SOLENOID SYSTEM
Contents Of Trouble

Open (no current flow) in LS-EPC solenoid circuit.


Failure code DXE0KA.

Response from controller

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.)

Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.


(Code No.: 01500 LS-EPC solenoid current.)

Phenomenon occurring on
machine
Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E223]

A.

2.

Specifications

No.

Readings

LS-EPC solenoid

Turn the engine ignition switch OFF for preparations

Disconnect V22 connection.

Hold ignition switch OFF during troubleshooting.


LS-EPC solenoid test
(internal
short
or
ground fault)

At connection V22, between (1) and (2)


Resistance

At connection V22, Between (1) and ground

7 - 14

Above 1 M

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch ON during this test.


A.
B.

3.

Open or high
resistance
Grounding fault
wiring harness
(Contact with 24V
grounding circuit)

Resistance

Between C03 (6) and V22 (1) and ground

Below 1

Between C03 (3), (13), (23) and V22 (2)

Below 1

Between C03 (6) and V22 (1) and ground

Below 1V

of
Voltage

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.


A.

Pump controller

20-354 1

Resistance

Between C03 (6) and (3), (13), (23)

7 - 14

PC400LC-7L

TROUBLESHOOTING

E223

Electrical Circuit Diagram for LS-EPC Solenoid

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.

Response from controller

The controller sets the F pump to 0 kg/cm2 (0 psi) for control.


When the failure cause disappears by itself, the machine operation returns to normal.

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

Tools and Procedures

broken. Accordingly, take extreme care when checking.


Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 01100: Front pump pressure.)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E224]

1.

Sensor power supply system defective

2.

Front pump pressure sensor defective (Internal defect)

Turn the engine ignition switch OFF for preparations

Ignition switch ON or keep the engine running during troubleshooting.


At connection A51, between (B) and (A) - power
A.

Front pump pressure


sensor test

supply
Voltage

Specifications

If error code 226 is displayed, carry out troubleshooting for it first.

At connection A51, Between (C) and (A) - signal

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.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect A51 connector from sensor.

Disconnect pump controller C01 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should be in the ON position during troubleshooting.


A.

B.

C.

4.

Disconnection
or
defective contact with
connector (Wiring
harness)

Resistance

Ground fault of wiring


harness (Contact with
ground circuit)

Resistance

Short in wiring harness


(Contact with 24V
circuit)

Voltage

Between C01 (22) and A51 (B)

Max. 1

Between C01 (10) and A51 (A)

Max. 1

Between C01 (8) and A51 (C)

Max. 1

Min. 1 MQ

Between C01 (22) and A51 (B) and ground

Max. 1V

Between C01 (8) and A51 (C) and ground

Max. 1V

4.5 - 5.5V

10

0.5 - 4.5V

11

Between C01 (8) and A51 (C) and ground

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

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.

Response from controller

The controller sets the R pump to 0 kg/cm2 (0 psi) for control.


When the failure cause disappears by itself, the machine operation returns to normal.

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

Tools and Procedures

broken. Accordingly, take extreme care when checking.


Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 01101: Rear pump pressure.)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E225]

1.

Sensor power supply system defective

2.

Front pump pressure sensor defective (Internal defect)

Turn the engine ignition switch OFF for preparations

Ignition switch ON or keep the engine running during troubleshooting.


At connection A52, between (B) and (A) - power
A.

Front pump pressure


sensor test

supply
Voltage

Specifications

If error code 226 is displayed, carry out troubleshooting for it first.

At connection A52, Between (C) and (A) - signal

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.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect A52 connector from sensor.

Disconnect pump controller C01 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should be in the ON position during troubleshooting.


A.

B.

C.

4.

Disconnection
or
defective contact with
connector (Wiring
harness)

Resistance

Ground fault of wiring


harness (Contact with
ground circuit)

Resistance

Short in wiring harness


(Contact with 24V
circuit)

Voltage

Between C01 (22) and A52 (B)

Max. 1

Between C01 (10) and A52 (A)

Max. 1

Between C01 (2) and A52 (C)

Max. 1

Min. 1 MQ

Between C01 (22) and A52 (B) and ground

Max. 1V

Between C01 (2) and A52 (C) and ground

Max. 1V

4.5 - 5.5V

10

0.5 - 4.5V

11

Between C01 (2) and A52 (C) and ground

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

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

Abnormal pressure sensor power supply (5V).


Failure code DH25KP.

Response from controller

Power to the power supply (5V) 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 pressure sensor signal is not input normally.


The error code of abnormality in the pressure sensor is displayed.

Relative information

---

Contents Of Trouble

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E226]

A.

2.

No.

Readings

If the error code goes off when one


Pressure sensor test
of the listed items (in order listed)
Disconnect the parts
is disconnected, that part is
shown at right in order.
defective.

Front pump pressure sensor - connector A51

Rear pump pressure sensor - connector A52

Arm IN PPC pressure sensor - connector S04

Bucket CURL PPC pressure sensor - connector S01

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.

A.

3.

Specifications

Pressure sensor defective (Internal short)

Turn the engine ignition switch OFF for preparations

Ignition switch ON during troubleshooting.

Ground fault of wiring


harness (Contact with
ground circuit)

Resistance

Between C01 (22) and A51 (B) and ground (F pump)

Min. 1 MQ

Between C01 22) and A52 (B) and ground (R pump)

Min. 1 MQ

Between C01 (22) and S04 (A) and ground (Bucket


CURL PPC)

Min. 1 MQ

Between C01 (22) and S01 (A) and ground (Arm IN


PPC)

Min. 1 MQ

4.5 - 5.5V

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

Ignition switch should be in the ON position for troubleshooting.


A.

Pump controller test

20-360 1

Voltage

Between C01 (22) and (10)

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.

Response from controller

The controller exercises a control equivalent to E mode.


If the failure cause disappears by itself, the signal input returns to normal.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E227]

Specifications

No.

Readings

Engine rotation sensor (Internal short)

Turn the engine ignition switch OFF for preparations

Ignition switch OFF during troubleshooting.


A.

Engine rotation sensor


test - internal short or
disconnected
sensor

Resistance
adjustment

Between ENE (1) and (2)

500 - 1,000

Between ene (1) and ground

Above 1M

2.

Engine
rotation
improper

3.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C02 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.

Refer to the section Adjusting Engine Rotation Sensor in this manual for inspection and adjustment.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

4.

Wiring harness
Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
24V circuit)

Voltage

Between C02 (40) and ENE (1)

Below 1

Between C02 (29), (39) and ENE (2)

Below 1

Between C02 (40) and ENE (1) and ground

Below 1V

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C02 and install T-adapter.

Ignition switch should be in the ON position for troubleshooting.


A.

Pump controller test

20-362 1

Resistance

Between C02 (40) and (29), (39)

500 - 1,000

Between C02 (40) and ground

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

Short in attachment return switching relay. (Pump controller system)


Failure code D196KB.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E228]

A.

2.

No.

Readings

Attachment
return
switching relay test internal short or disconnected

Resistance

Between R20, between (1) and (2)

100 - 500

Below 1V

Working mode - Other than B mode

20 30V

Working mode - B mode

Below 1V

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C02 and install T-adapter.

Ignition switch should remain in the ON position during troubleshooting.


A.

3.

Specifications

Attachment return switching relay (Internal short)

Turn the engine ignition switch OFF for preparations

Ignition switch OFF during troubleshooting.

Wiring harness
Short (Contact with
24V circuit)

Voltage

Between C02 (8) and R20 (2) and ground

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C02 and install T-adapter.

Ignition switch should be in the ON position for troubleshooting.


A.

Pump controller test

20-364 1

Voltage

C02 (8) and


ground

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

Short in PC-EPC solenoid. (Pump controller system)


Failure code DXA0KB.

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.)

Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.


(Code No.: 01300 PC-EPC solenoid current)
If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode
equivalent to E mode by turning the emergency pump drive switch to the emergency position. (At that time the monitor
panel continues to display Error Code No. E233, but this is not abnormal.)
Have the emergency driving switch in normal during the troubleshooting.

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E232]

A.

2.

Readings

PC-EPC solenoid test internal short or


disconnected

At V21, between (1) and (2)


Resistance

7 - 14

Above 1 M

Above 1 M

Above 1 M

Between C03 (16) and S25 (3) and ground

Above 1 M

Between S25 (2) and V21 (1) and ground

Above 1 M

At V21, between (1) and ground

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

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should remain in the OFF position during troubleshooting.


A.

4.

No.

Emergency pump driving switch

Turn the engine ignition switch OFF for preparations

Disconnect pump controller S25 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

Specifications

PC-EPC solenoid (Internal short)

Turn the engine ignition switch OFF for preparations

Ignition switch OFF during troubleshooting.

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Pump controller test

20-366 1

Resistance

At C03, between (16) and (3), (13), (23)


At C03, between (16) and ground

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

No current flow to PC-EPC solenoid circuit. (Pump controller system)


Failure code DXA0KA.

Response from controller

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.)

Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.


(Code No.: 01300 PC-EPC solenoid current)
If there is no abnormality with the solenoid or any of the wiring harness, the machine can be operated in a working mode
equivalent to E mode by turning the emergency pump drive switch to the emergency position.

Phenomenon occurring on
machine
Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E233]

A.

2.

Specifications

No.

Readings

PC-EPC solenoid (Internal short)

Turn the engine ignition switch OFF for preparations

Ignition switch OFF during troubleshooting.


PC-EPC solenoid test internal short or
disconnected

At V21, between (1) and (2)


Resistance

At V21, between (1) and ground

7 - 14

Above 1 M

Emergency pump driving switch

Turn the engine ignition switch OFF for preparations

Disconnect pump controller S25 and install T-adapter.

Ignition switch OFF during troubleshooting.


Emergency pump drive switch
A.

3.

Emergency
pump
drive switch test internal short or
disconnected

- Normal
Resistance

- Emergency

At S25, between (2) and (3)

Below 1

Above 1 M

Below 1

Above 1 M

Between C03 (16) and S25 (3)

Below 1

Between S25 (2) and V21 (1)

Below 1

At C03, between (3), (13), (23) and S25 (6)

Below 1

Between S25 (5) and V21 (2)

Below 1

10

Between C03 (16) and S25 (3) and ground

Below 1V

11

Between S25 (2) and V21 (1) and ground

Below 1V

12

7 - 14

13

- Normal
- Emergency

At S25, between (5) and (6)

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and S25 RH console emergency switch and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

4.

Wiring harness
Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
24V circuit)

Voltage

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Pump controller test

20-368 1

Resistance

At C03, between (16) and (3), (13), (23)

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E238]

1.

Fuse No. 2 fault

2.

Attachment return switching relay (Internal short)

Turn the engine ignition switch OFF for preparations

Disconnect R20 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

No.

Readings

Resistance

At R20, between (1) and (2)

100 - 500

Between C02 (8) and R20 (2)

Below 1

At R20 (1) to J03 to FB1-2 outlet

Below 1

Between C02 (8) and R20 (2) and ground

Above 1

Between R20 (1) to J03 to FB1-2 and ground

Above 1

20 - 30V

Below 1V

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C02 and R20 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

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

With ignition switch in OFF position.

Disconnect pump controller C02 and install T-adapter.

Ignition switch should be in the ON position for troubleshooting.


Working mode
A.

Pump controller test

Voltage

Other than B
mode
B mode

20-370 1

At C02, between (8) and ground

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E245]

A.

2.

No.

Readings

Attachment oil flow


rate EPC valve test internal short or
disconnected

At V30, between (1) and (2)


Resistance

At V30, between (1) and grounding

7 - 14

Above 1

Above 1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Attachment oil flow rate EPC valve (Internal short)

Turn the engine ignition switch OFF for preparations

Disconnect V30 and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Between C03 (26) and V30 (1) and ground

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Pump controller test

20-372 1

Resistance

At C03, between (26) and (3), (13), (23)


At C03, between (26) and grounding

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E246]

A.

2.

Specifications

No.

Readings

Attachment oil flow rate EPC valve (Internal short)

Turn the engine ignition switch OFF for preparations

Disconnect V30 and install T-adapter.

Ignition switch OFF during troubleshooting.


Attachment oil flow
rate EPC valve test internal short or
disconnected

At V30, between (1) and (2)


Resistance

7 - 14

Above 1

Between C03 (26) and V30 (1) and grounding

Below 1

Between C03 (3), (13), (23) and V30 (2) and grounding

Below 1

Between C03 (26) and V30 (1) and ground

Below 1V

7 - 14

At V30, between (1) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

3.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
24V circuit)

Voltage

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C03 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Pump controller test

20-374 1

Resistance

At C03, between (26) and (3), (13), (23)

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.

Response from controller

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

Tools and Procedures

broken. Accordingly, take extreme care when checking.


Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 07200 Arm IN PPC pressure)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E247]

1.

Sensor power supply system

2.

Arm IN PPC pressure sensor (Internal short)

Turn the engine ignition switch OFF for preparations

Disconnect S04 and install T-adapter.

Ignition switch ON or keep engine running during troubleshooting.


A.

3.

Arm IN PPC pressure


sensor test - internal
short or disconnected

Specifications

No.

Readings

If error code 226 is displayed, carry out troubleshooting for it first.

Voltage

S04 Power supply, between (A) and (C)

4.5 5.5V

S04 Signal, between (B) and (C)

0.5 4.5V

Between C01 (22) and S04 (A)

Max. 1

Between C01 (10) and S04 (C)

Max. 1

Between C01 (19) and S04 (B)

Max. 1

Between C01 (19) and S04 (B) and ground

Min. 1M

At C01 (22) and S04 (A) and ground

Max. 1V

At C01 (19) and S04 (B) and ground

Max. 1V

4.5 5.5V

0.5 4.5V

10

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

4.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


ground fault (Contact
with grounding circuit)

Resistance

Wiring harness test


Short (Contact with
24V circuit)

Voltage

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

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.

Response from controller

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

Tools and Procedures

broken. Accordingly, take extreme care when checking.


Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No.: 07300 Bucket CURL PPC pressure)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E248]

1.

Sensor power supply system

2.

Bucket CURL (Dig) PPC pressure sensor (Internal defect)

Turn the engine ignition switch OFF for preparations

Disconnect S01 and install T-adapter.

Ignition switch ON or keep engine running during troubleshooting.


A.

Bucket CURL (Dig)


PPC pressure sensor
test - internal short or
disconnected

Specifications

No.

Readings

If error code 226 is displayed, carry out troubleshooting for it first.

Voltage

S01 Power supply, between (1) and (3)

4.5 5.5V

S01 Signal, between (2) and (3)

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.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect pump controller C01, S01 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

4.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


ground fault (Contact
with grounding circuit)

Resistance

Wiring harness test


Short (Contact with
24V circuit)

Voltage

Between C01 (22) and S01 (1)

Max. 1

Between C01 (10) and S01 (3)

Max. 1

Between C01 (19) and S01 (2)

Max. 1

Between C01 (19) and S01 (2) and ground

Min. 1M

At C01 (22) and S01 (1) and ground

Max. 1V

At C01 (19) and S01 (2) and ground

Max. 1V

Pump controller

With ignition switch in OFF position.

Disconnect pump controller C01 and install T-adapter.

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.

Response from controller

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

Relative information

---

Contents Of Trouble

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E257]

Specifications

No.

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect P70, C02, CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


ground fault (Contact
with grounding circuit)
Resistance

C.

Wiring harness test


Short (Contact with
24V circuit)
Voltage

2.

Below 1

Below 1

Between P70 (15) and CB2 (32)

Below 1

Between P70 (15) and C02 (32)

Below 1

Between P70 (16) and CB2 (22)

Above 1M

Between P70 (16) and C02 (22)

Above 1M

Between P70 (16) and related circuits and grounding

Above 1M

Between P70 (15) and CB2 (32)

Above 1M

Between P70 (15) and C02 (32)

Above 1M

Between P70 (15) and related circuits and grounding

Above 1M

10

Between P70 (16) and CB2 (22)

Below 1V

11

Between P70 (16) and C02 (22)

Below 1V

12

Between P70 (16) and related circuits and grounding

Below 1V

13

Between P70 (15) and CB2 (32)

Below 1V

14

Between P70 (15) and C02 (32)

Below 1V

15

Between P70 (15) and related circuits and grounding

Below 1V

16

At K30, between (1) and (2)

40 - 80

17

At K31, between (1) and (2)

40 - 80

18

CAN terminal resistor

Turn the ignition switch OFF for the preparations.

Disconnect K30 and K31 CAN connectors and install T-adapter.

Hold ignition switch in the OFF position during the troubleshooting.


A.

3.

Between P70 (16) and CB2 (22)


Between P70 (16) and C02 (22)

CAN terminal resistor


test

Resistance

Monitor panel, engine controller or pump controller

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

Short in battery relay system


Failure code D110KB.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E315]

A.
2.

Readings

Battery relay test

Resistance

Approximately
100

Min. 1M

At diode D1, between (1) and (5) reversing meter lead


polarity each time to check.

Continuity one
way only?

Yes or No

At diode D1, between (2) and (6) reversing meter lead


polarity each time to check.

Continuity one
way only?

Yes or No

Between C03 (4), D01, J01, battery relay terminal BR and


grounding

Min. 1M

Between C03 (4) and ignition switch terminal BR and


grounding

Min. 1M

Between C03 (4) and D01 (2) and grounding

Min. 1M

20 - 30V
(for 0.5 sec.)

At battery relay
unit

Between BR and E
Between BR and grounding

Diode test

Resistance

Wiring harness assembly

With ignition switch in OFF position.

Disconnect C03 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

4.

No.

Diode

With ignition switch in OFF position.

Disconnect D01 diode connector and isolate diode.


A.

3.

Specifications

Battery relay

Turn the ignition switch OFF for the preparations.

Disconnect A20 and A21 wires from battery relay.

Hold the ignition switch in the OFF position during the troubleshooting.

Zero meter leads for proper readings.

Wiring harness test


ground fault (Contact
with grounding circuit)

Resistance

Pump controller

With ignition switch in OFF position.

Ignition switch should remain in the ON position during troubleshooting.


A.

Pump controller

20-382 1

Voltage

Ignition switch
ON OFF

At C03, between (4) and grounding

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.

Response from controller

The machine is driven with limited output.


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 lower idling.

Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
(Code No.: 01002 Engine speed)

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E91B]

A.

2.

No.

Readings

Engine Ne speed
sensor test - internal
short or disconnected

At NE, between (1) and (2)


Resistance

85 - 210

Above 1

Between CB2 (36) and NE (2)

Below 1

Between CB2 (26) and NE (1)

Below 1

Between CB2 (36) aand NE (2) and ground

Above 1

Between CB2 (26) aand NE (1) and ground

Above 1

At NE, between (1), (2) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Engine Ne speed sensor

Turn the engine ignition switch OFF for preparations

Disconnect NE and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Engine controller test

20-384 1

Resistance

At CB2, between (36) and (26)


At CB2, between (36), (26) and grounding

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.

Response from controller

The machine is driven with limited output.


Control is carried out with the Ne sped sensor signal.

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.

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E91C]

A.

2.

No.

Readings

Engine G speed
sensor test - internal
short or disconnected

Resistance

At G, between (1) and (2)

1.4 - 3.5k

At G, between (1), (2) and grounding

Above 1

Between CB2 (35) and G (2)

Below 1

Between CB2 (25) and G (1)

Below 1

Between CB2 (35) aand G (2) and ground

Above 1

Between CB2 (25) aand G (1) and ground

Above 1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Engine G speed sensor

Turn the engine ignition switch OFF for preparations

Disconnect G connector and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch should be in the OFF position for troubleshooting.


A.

Engine controller test

20-386 1

Resistance

At CB2, between (35) and (25)

1.4 - 3.5k

At CB2, between (35) and grounding

Above 1

At CB2, between (25) and grounding

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

Response from controller


Phenomenon occurring on
machine

Relative information

Tools and Procedures

Control is carried out with the default model (PC400).


Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine starting switch is once turned OFF.

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)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E920]

No.

Readings

Model selection
connector test internal short or
disconnected

Resistance

At CB5, between (2) and (8)

Above 1

At CB5, between (3) and (8)

Above 1

At CB5, between (4) and (8)

Above 1

At CB5, between (5) and (8)

Above 1

At CB5, between (6) and (8)

Above 1

At CB5, between (7) and (8)

Above 1

At CB5, between (1) and (8)

Below 1

Between CB1 (3) and CB5 (1)

Below 1

Between CB2 (1) and CB5 (8)

Below 1

Between CB1 (23) aand CB5 (2) and ground

Above 1

10

Between CB1 (17) aand CB5 (3) and ground

Above 1

11

Between CB1 (23) and CB2 (1)

20 30V

12

Between CB1 (17) and CB2 (1)

20 30V

13

Between CB! (3) and CB2 (1)

Below 1V

14

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB1 and CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Model selection connector

Turn the engine ignition switch OFF for preparations

Disconnect CB5 connector and install T-adapter.

Ignition switch OFF during troubleshooting.

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.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch should be held in the ON position for troubleshooting.


CB1, CB2
A.

Engine controller test

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

Response from controller


Phenomenon occurring on
machine

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 normal operation is continued.


Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine ignition switch is turned OFF.

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

Circuit Diagnostic Procedures For Code [E921]

Specifications

No.

Readings

1.

Model selection connector system defective

If error code E920 is displayed, carry out troubleshooting for it.

2.

Engine controller defective

Engine controller may be defective. (Since trouble is in the controller, troubleshooting cannot be
carried out.)

3.

Pump controller defective

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

Response from controller

Phenomenon occurring on
machine
Relative information

Tools and Procedures

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.

The engine speed cannot be controlled.

Input from the fuel control dial (voltage) can be checked in the monitoring function.
(Code No.: 03000 Fuel control dial voltage)

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E931]

A.

2.

Specifications

No.

Readings

Fuel control dial defective

Turn the engine ignition switch OFF for preparations

Disconnect E06 connector and install T-adapter.

Ignition switch ON or keep the engine running during troubleshooting.


Fuel control dial test internal short or
disconnected

Resistance

At E06, between (1) and (3)

4.0 6.0k

At E06, between (1) and (2)

0.25 7.0k

At E06, between (3) and (2)

0.25 7.0k

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and E06 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

3.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Wiring harness
Contact with 24V
circuit

Voltage

Between CB2 (19) and E06 (1)

Below 1

Between CB2 (10) and E06 (2)

Below 1

Between CB2 (29) and E06 (3)

Below 1

Between CB2 (39) and E06 (3)

Below 1

Between CB2 (19) and E06 (1) and ground

Above 1

Between CB2 (10) and E06 (2) and ground

Above 1

Between CB2 (19) and E06 (1) and ground

Below 1V

10

Between CB2 (10) and E06 (2) and ground

Below 1V

11

At CB2, Between (19) and (29)

4.6 - 5.4V

12

At CB2, Between (19) and (39)

4.6 - 5.4V

13

At CB2, Between (10) and (29)

0.3 - 4.5V

14

At CB2, Between (10) and (39)

0.3 - 4.5V

15

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch ON or keep the engine running during troubleshooting.

A.

Engine controller test

20-392 1

Voltage

PC400LC-7L

TROUBLESHOOTING

E931

Electrical circuit diagram related to fuel control dial

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E934]

A.

2.

No.

Readings

Engine water high


temperature sensor test
- internal short or
disconnected

Resistance

At TWH, between (1) and (2)

3.5 90k

At TWH, between (1) and grounding

Above 1

At TWH, between (2) and grounding

Above 1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and TWH and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Engine water high temperature sensor defective

Turn the engine ignition switch OFF for preparations

Disconnect TWH connector and install T-adapter.

Ignition switch ON or keep the engine running during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Between CB2 (27) and TWH (1)

Below 1

Between CB2 (29) and TWH (2)

Below 1

Between CB2 (39) and TWH (2)

Below 1

Above 1

Between E12 (27) and TWH (1) and ground

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch OFF during troubleshooting.

A.

Engine controller test

20-394 1

Resistance

At CB2, Between (27) and (39)

3.5k - 90k

At CB2, Between (29) and (39)

3.5k - 90k

At CB2, Between (27) and grounding

Above 1

10

At CB2, Between (29) and grounding

Above 1

11

At CB2, Between (39)and grounding

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))

Response from controller


Phenomenon occurring on
machine

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E96A]

A.

2.

No.

Readings

Engine water low


temperature sensor test
- internal short or
disconnected

0.3 9k

At TWL, between (1) and grounding

Above 1

At TWL, between (2) and grounding

Above 1

At TWL, between (1) and (2)


Resistance

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and TWL and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Engine water high temperature sensor defective

Turn the engine ignition switch OFF for preparations

Disconnect TWL connector and install T-adapter.

Ignition switch ON or keep the engine running during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Between CB2 (37) and TWL (1)

Below 1

Between CB2 (29) and TWL (2)

Below 1

Between CB2 (39) and TWL (2)

Below 1

Above 1

At CB2, Between (37) and (39)

0.3 9k

At CB2, Between (29) and (39)

0.3 9k

At CB2, Between (29) and grounding

Above 1

10

At CB2, Between (37) and grounding

Above 1

11

At CB2, Between (39)and grounding

Above 1

12

Between E12 (37) and TWL (1) and ground

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch OFF during troubleshooting.

A.

Engine controller test

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E936]

A.

B.

2.

No.

Readings

Engine water low oil


pressure switch test internal short or
disconnected
Engine water high oil
pressure switch test internal short or
disconnected

Engine
Resistance

PSL
Below 1

Above 1

Below 1

Above 1

Between CB1 (21) and PSL

Below 1

Between CB1 (15) and PSH

Below 1

Between CB1 (21) and PSL and ground

Above 1

Between CB1 (15) and PSH and ground

Above 1

Stopped
Low idling

Between terminal and grounding

Engine
Resistance

PSH

Stopped
Running at 1,300 Between terminal and grounding
rpm or higher

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB1 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Engine low oil pressure switch defective

Turn the engine ignition switch OFF for preparations

Ignition switch OFF or keep the engine running during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB1 and install T-adapter.

Ignition switch ON and start the engine during troubleshooting.


Engine
Stopped
A.

Engine controller test

---

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.

Response from controller

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E93C]

A.

2.

Specifications

No.

Readings

Boost pressure sensor defective

Turn the engine ignition switch OFF for preparations.

Disconnect PIM boost pressure sensor.

Ignition switch ON or keep the engine running during troubleshooting.


Engine boost
pressure sensor test internal short or
disconnected

PIM
Voltage

Power supply

Between (3) and (1)

4.6 5.4V

Signal

Between (2) and (1)

0.5 - 4.5V

Between CB2 (9) and PIM (3)

Below 1

Between CB2 (29) and PIM (1)

Below 1

Between CB2 (39) and PIM (1)

Below 1

Between CB2 (20) and PIM (2)

Below 1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

3.

Wiring harness test


Disconnection
or
defective contact with
connector
Wiring harness
Short (Contact with
grounding circuit)
Wiring harness
Contact with 24V
circuit

Resistance

Resistance

Voltage

Between CB2 (9) and PIM (3) and ground

Above 1

Between CB2 (9) and related circuits and ground

Above 1

Between CB2 (20) and PIM (2) and ground

Above 1

Below 1V

10

Between CB2 (9) and PIM (3)


Between CB2 (9) and related circuits and ground
Between CB2 (20) and PIM (2) and ground

Below 1V

11

Below 1V

12

At CB2, between (9) and (29)

4.6 - 5.4V

13

At CB2, between (9) and (39)

4.6 - 5.4V

14

At CB2, between (20) and (29)

0.3 - 4.7V

15

At CB2, between (20) and (39)

0.3 - 4.7V

16

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch ON and start the engine during troubleshooting.

A.

Engine controller test

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.

Response from controller

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 temperature is low.


The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.

Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
(Code No.: 14201 Fuel temperature sensor voltage)

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E93D]

A.

2.

No.

Readings

Fuel temperature
sensor test - internal
short or disconnected

At THL, between (1) and (2)


Resistance

0.3k - 9k

At THL, between (1) and grounding

Above 1

At THL, between (2) and grounding

Above 1

Between CB2 (17) and THL (13)

Below 1

Between CB2 (29) and THL (2)

Below 1

Between CB2 (39) and THL (2)

Below 1

Above 1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Fuel temperature sensor defective

Turn the engine ignition switch OFF for preparations.

Disconnect THL connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness
Short (Contact with
grounding circuit)

Resistance

Between CB2 (17) and THL (1) and ground

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch OFF during troubleshooting.

A.

Engine controller test

20-402 1

Resistance

At CB2, between (17) and (39)

0.3k - 9k

At CB2, between (29) and (39)

0.3k - 9k

At CB2, between (17) and (39) and grounding

Above 1

10

At CB2, between (29) and (39) and grounding

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.

Response from controller

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

Relative information

---

Contents Of Trouble

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E953]

Specifications

No.

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect P70, C02, CB2 connectors and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

2.

Wiring harness
Short (Contact with
grounding circuit)

Wiring harness
Contact with 24V
circuit

Resistance

Resistance

Voltage

Between P70 (16) and CB2 (22)

Below 1

Between P70 (16) and C02 (22)

Below 1

Between P70 (15) and CB2 (32)

Below 1

Between P70 (15) and C02 (32)

Below 1

Between P70 (16) and CB2 (22) and ground

Above 1

Between P70 (16) and C02 (22) and ground

Above 1

Between P70 (16) and related circuits and ground

Above 1

Between P70 (15) and CB2 (32) and ground

Above 1

Between P70 (15) and C02 (32) and ground

Above 1

Between P70 (15) and related circuits and ground

Above 1

10

Between P70 (16) and CB2 (22)

Below 1V

11

Between P70 (16) and C02 (22)

Below 1V

12

Between P70 (16) and related circuits and ground

Below 1V

13

Between P70 (15) and CB2 (32) and ground

Below 1V

14

Between P70 (15) and C02 (32) and ground

Below 1V

15

Between P70 (15) and related circuits and ground

Below 1V

16

CAN terminal resister

With ignition switch in OFF position.

Disconnect K30 and K31 connectors and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

Wiring harness test


Disconnection
or
defective contact with
connector

CAN terminal resister


test

Resistance

Monitor panel, engine controller or pump


controller defective

20-404 1

At K30, between (1) and (2)

40 - 80

17

At K31, between (1) and (29)

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.

Response from controller

Ignition switch signal is recognized to be OFF.


When the failure cause disappears by itself, the machine operation returns to normal.

Phenomenon occurring on
machine

The machine operates normally.

Input from ignition switch signal C (ON or OFF) can be checked in the monitoring function.
(Code No.: 17400 Engine controller input)

Relative information

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E954]

A.

2.

No.

Readings

Ignition switch test internal short or


disconnected

Ignition switch
Resistance

Above 1

Below 1

Between ignition switch terminal C, J01 and CB1

Below 1V

Between ignition switch terminal C and C01 (17)

Below 1V

Between ignition switch terminal C and P01 (4)

Below 1V

Between ignition switch terminal C and R11 (5)

Below 1V

Between ignition switch terminal C and related circuits

Below 1V

Between ignition switch terminal C and grounding

Below 1V

Between
terminal B and terminal C

OFF
START

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

A.

3.

Specifications

Ignition switch defective

Turn the engine ignition switch OFF for preparations.

Disconnect THL connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Short (Contact with
24V ground circuit)

Voltage

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB1 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

20-406 1

Voltage

CB1

Ignition switch

Between (20) and grounding ON (Engine is running)

--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.

Response from controller

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

The output lowers (The pump absorption torque is reduced).


If the working load increases, the engine may stall.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E955]

Specifications

No.

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect P02, C02, CB2 connectors and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

C.

2.

Wiring harness
Short (Contact with
grounding circuit)

Wiring harness
Contact with 24V
circuit

Resistance

Between P02 (9) and CB2 (21)

Below 1

Between P02 (9) and C02 (21)

Below 1

Below 1

Between P02 (10) and C02 (21)

Resistance

Voltage

Between P02 (9) and CB2 (21) and ground

Above 1

Between P02 (10) and CB2 (31) and ground

Above 1

Between P02 (9) and C02 (21) and ground

Above 1

Between P02 (10) and C02 (21) and ground

Above 1

Between P02 (9) and related circuits and ground

Above 1

Between P02 (10) and related circuits and ground

Above 1

Between P02 (9) and CB2 (21) and ground

Below 1V

10

Between P02 (10) and CB2 (31) and ground

Below 1V

11

Between P02 (9) and C02 (21) and ground

Below 1V

12

Between P02 (10) and C02 (21) and ground

Below 1V

13

Between P02 (9) and related circuits and ground

Below 1V

14

Between P02 (10) and related circuits and ground

Below 1V

15

At P02, between (9) and (20)

6 - 9V

16

At P02, between (10) and (20)

6 - 9V

17

At CB2, between (21) and (11)

6 - 9V

18

At CB2, between (31) and (11)

6 - 9V

19

Monitor panel

With ignition switch in OFF position.

Disconnect P02 connector and install T-adapter.

Ignition switch ON during troubleshooting.


A.

3.

Wiring harness test


Disconnection
or
defective contact with
connector

Monitor panel test

Voltage

Engine controller

With ignition switch in OFF position.

Disconnect CB2 connector and install T-adapters.

Ignition switch ON during troubleshooting.


A.

Engine controller test

20-408 1

Voltage

PC400LC-7L

TROUBLESHOOTING
Steps
4.

E955

Circuit Diagnostic Procedures For Code [E955]

Specifications

No.

Readings

Pump controller

With ignition switch in OFF position.

Disconnect C02 connector and install T-adapters.

Ignition switch ON during troubleshooting.


A.

Pump controller test

Voltage

At C02, between (21) and (31)

6 - 9V

20

Electrical circuit diagram related to S-NET communication

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.

Response from controller

None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.

Phenomenon occurring on
machine

The engine stalls.


The engine cannot be started.

Relative information

---

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E956]

Specifications

1.

Circuit breaker 7 defective If circuit breaker is turned OFF, the circuit probably has grounding fault, etc. (See cause 3B.)

2.

Engine controller power supply relay defective

Turn the engine ignition switch OFF for preparations.

Ignition switch ON during troubleshooting.


A.

3.

---

Readings

Replace the power supply relay, R22, with another one. If the condition becomes normal, the relay is
defective.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and R22 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

A.

B.

4.

Engine
controller
power supply relay test
- internal short or
disconnected

No.

Wiring harness test


Disconnection
or
defective contact with
connector

Wiring harness test


Short (Contact with
ground circuit)

Resistance

Resistance

Between CB3 (1) and R22 (5)

Below 1

Between CB3 (2) and R22 (5)

Below 1

Between CB3 (21) and R22 (5)

Below 1

Between R22 (3) and CB3 (1), (2), (21)

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

Between CB3 (1), (2), (21) and R22 (3)

Above 1M

Between R22 (5) and battery relay B and ground

Above 1M

Between R22 (1) and H15 (5)

Above 1M

Between R22 (1) and BCB1 (13), (19)

Above 1M

10

Between R22 (1) and related circuits and grounding

Above 1M

11

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


CB3
A.

Engine controller test

20-410 1

Voltage

Between (1), (2), (21) and


(11), (31), (32)

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.

Response from controller

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 temperature is low.


The over heat protection function does not operate.
If the controller is also defective, the engine does not stop.

Relative information

---

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E957]

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.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and R22 and install T-adapters.

Ignition switch should remain in the ON position during troubleshooting.


A.

3.

Specifications

Engine controller power supply relay defective

Turn the engine ignition switch OFF for preparations.

Ignition switch ON during troubleshooting.

Wiring harness test


Short (Contact with
24V ground circuit)

Voltage

Between CB3 (1), (2), (21) and R22 (3) and ground

Below 1V

Between R22 (1) and J03 or related circuits and ground

Below 1V

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


CB3
A.

Engine controller test

20-412 1

Voltage

Between (1), (2), (21) and


(11), (31), (32)

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.

Response from controller

None in particular.
When the failure cause disappears by itself, the machine operation returns to normal.

Phenomenon occurring on
machine

Setting of the fuel injection amount adjustment switch cannot be changed.

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)

Tools and Procedures

Relative information

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [E95A]

Specifications

No.

Readings

1.

Setting of fuel injection amount adjustment


If fuel injection amount adjustment switch 1 (right) or 2 (left) is set in [F], its setting is wrong.
switch of engine controller defective

2.

Engine controller defective

20-414 1

If the cause is not detected, engine controller may be defective.

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.

Power to the fuel supply pump PCV1 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 first 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

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E970]

A.

2.

Specifications

No.

Readings

Fuel supply pump PCV1 defective

Turn the engine ignition switch OFF for preparations.

Disconnect PCV1 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


Fuel supply pump
PCV1 test - internal
short or disconnected

At PCV1, between (1) and (2)


Resistance

2.3 - 5.3

Above 1

Above 1

Between CB3 (2) and PCV1 (1)

Below 1V

Between CB3 (22) and PCV1 (2)

Below 1V

At PCV1, between (1) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and PCV1 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

3.

Wiring harness test


Contact with
grounding circuit
Wiring harness
Short (Contact with
24V grounding circuit)

Resistance

Voltage

Between CB3 (12) and PCV1 (1)

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

20-416 1

Resistance

At CB3, between (12) and (22)


At CB3, between (12) and (22) and grounding

2.3 - 5.3

Above 1

PC400LC-7L

TROUBLESHOOTING

E970

Electrical circuit diagram related to fuel supply pump PCV1

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.

Power to the fuel supply pump PCV2 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 first 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

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E91]

A.

2.

Specifications

No.

Readings

Fuel supply pump PCV2 defective

Turn the engine ignition switch OFF for preparations.

Disconnect PCV1 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


Fuel supply pump
PCV2 test - internal
short or disconnected

At PCV2, between (1) and (2)


Resistance

2.3 - 5.3

Above 1

Above 1

Between CB3 (13) and PCV2 (1)

Below 1V

Between CB3 (23) and PC2 (2)

Below 1V

At PC2, between (1) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and PCV1 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

Ignition switch should remain in the ON position during troubleshooting.


A.

B.

3.

Wiring harness test


Contact with
grounding circuit
Wiring harness
Short (Contact with
24V grounding circuit)

Resistance

Voltage

Between CB3 (13) and PCV2 (1)

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

20-418 1

Resistance

At CB3, between (13) and 3)


At CB3, between (13) and (23) and grounding

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

Fuel supply pump PCV1 circuit is disconnected. (Engine controller system)


Failure code AD11KA.

Power to the fuel supply pump PCV1 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 first 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

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E974]

A.

2.

No.

Readings

Fuel supply pump


PCV1 test - internal
short or disconnected

At PCV1, between (1) and (2)


Resistance

2.3 - 5.3

Above 1

Below 1

Between CB3 (22) and PCV1 (2)

Below 1

Between CB3 (22) and PCV1 (2)

Above 1

At PCV1, between (1) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and PCV1 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Fuel supply pump PCV1 defective

Turn the engine ignition switch OFF for preparations.

Disconnect PCV1 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Between CB3 (12) and PCV1 (1)

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

20-420 1

Resistance

At CB3, between (12) and (22)


At CB3, between (12) and (22) and grounding

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

Fuel supply pump PCV2 circuit is disconnected. (Engine controller system)


Failure code AD51KA.

Power to the fuel supply pump PCV2 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 first 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

Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E975]

A.

2.

No.

Readings

Fuel supply pump


PCV2 test - internal
short or disconnected

At PCV2, between (1) and (2)


Resistance

2.3 - 5.3

Above 1

Below 1

Between CB3 (23) and PCV2 (2)

Below 1

Between CB3 (23) and PCV2 (2)

Above 1

At PCV2, between (1) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and PCV21 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

3.

Specifications

Fuel supply pump PCV2 defective

Turn the engine ignition switch OFF for preparations.

Disconnect PCV2 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Between CB3 (13) and PCV2 (1)

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

20-422 1

Resistance

At CB3, between (13) and (23)


At CB3, between (13) and (23) and grounding

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.

Response from controller

The machine is driven with limited output.


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 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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E977]

A.

2.

No.

Readings

Common rail fuel


pressure sensor test internal short or
disconnected

Voltage

At PFUEL, between (3) and (1), power supply

4.6 - 5.4V

At PFUEL, (2) and (1), signal

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.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB2 and PFUEL and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

B.

C.

3.

Specifications

Common rail fuel pressure sensor defective

Turn the engine ignition switch OFF for preparations.

Disconnect PFUEL connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Wiring harness test


Contact with 24V circuit

Voltage

Between CB2 (9) and PFUEL (3)

Below 1

Between CB2 (39) and PFUEL (1)

Below 1

Between CB2 (40) and PFUEL 2)

Below 1

Between CB2 (9) and PFUEL (3)

Above 1

Between CB2 (9) and related circuits and grounding

Above 1

Between CB2 (40) and PFUEL (2) and grounding

Above 1

Between CB2 (9) and PFUEL (3)

Below 1V

Between CB2 (9) and related circuits and grounding

Below 1V

10

Between Cb2 (40) and PFUEL (2) and grounding

Below 1V

11

At CB2, between (9) and (39)

4.6 - 5.4V

12

At CB2, between (40) and (39)

0.7 - 4.5V

13

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

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.

Response from controller

The machine is driven with limited output.


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 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

Standard value in normal and references for troubleshooting

1.

Related systems defective

If any other error code or failure code is displayed, carry out troubleshooting for it first.

2.

Fuel used improper

Fuel used may be improper. Check it directly.

3.

Electric system or common rail fuel


pressure sensor defective

Carry out troubleshooting for error code E977.

4.

Mechanical system of common rail fuel


The common rail fuel pressure sensor may have a mechanical defect. Check it directly.
pressure sensor defective

5.

Overflow valve defective

The overflow valve may have trouble of breakage of spring, wear of seat or fixing of ball. Check it
directly.

6.

Overflow piping clogged

The overflow piping may be clogged. Check it directly.

7.

Pressure limiter defective

The pressure limiter may have a mechanical defect. Check it directly.

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.

Response from controller

The machine is driven with limited output.


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 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

Standard value in normal and references for troubleshooting


Carry out troubleshooting for error code E979.

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.

The machine is driven with limited output.


Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.

The engine does not start easily when temperature is low.


The overheat protection function does not operate.
If the controller is also defective, the engine does not stop.

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

Standard value in normal and references for troubleshooting

1.

Related systems defective

If any other error code or failure code is displayed, carry out troubleshooting for it first.

2.

Fuel used improper

Fuel used may be improper. Check it directly.

3.

Fuel low pressure circuit device defective

A low pressure circuit device may be defective. Referring to Note 1, carry out troubleshooting.

4.

Fuel filter/strainer clogged

The fuel filter /strainer may be clogged. Referring to Note 2, carry out troubleshooting.

5.

Electrical system of fuel supply pump PCV1


Carry out troubleshooting for error codes E970, E971,E974 and E975.
defective

6.

Fuel supply pump defective

7.

Common rail fuel pressure sensor defective The common rail fuel pressure sensor may be defective. Check it directly.

The fuel supply pump may be defective. Check it directly.

8.

Pressure limiter defective

The pressure limiter may have a mechanical defect. Check it directly.

9.

Fuel injector defective

The fuel injector may be defective. Referring to Note 3. Check it directly.

Note 1: Check the low-pressure circuit devices for the following points.
1.

Insufficiency of fuel.

2.

Fixing and wear of feed pump and clogging of filter.

3.

Leakage from and clogging of low-pressure fuel piping.

4.

Malfunction of bypass valve and installation of wrong part (See Fig. 1).

5.

Clogging of fuel filter.

6.

Entry of fuel in oil pan (Fuel leakage in head cover).


Fuel low-pressure circuit pressure: 0.15 0.3 MPa {1.5 3.0 kg/cm2}(21.3 - 42.6 psi).

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)

Limit of spill (cc/min)

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 machine is driven with limited output.


Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.

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

Standard value in normal and references for troubleshooting


Carry out troubleshooting for error code E97B.

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 machine is driven under the normal control.


Even after the failure cause disappears by itself, the machine operation does not return to normal, unless the engine
ignition switch is turned OFF.

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

Standard value in normal and references for troubleshooting


Carry out troubleshooting for error code E97B.

20-431 1

TROUBLESHOOTING

E980

12

E980
ENGINE CONTROLLER ABNORMALITY

The controller has an abnormality in it. (Engine controller system)


Failure code DB20KT.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E977]

A.

2.

Specifications

No.

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


Wiring harness test
Disconnection
or
defective contact with
connector

Engine controller defective

20-432 1

Resistance

Between CB3 (11) and grounding

Below 1

Between CB3 (31) and grounding

Below 1

Between CB3 (32) and grounding

Below 1

If cause 1 is not detected, the engine controller may be defective.


(Since trouble is in the engine controller, troubleshooting cannot be carried out.)

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

Fuel injector 1 circuit is disconnected. (Engine controller system)


Failure code ADA1KA.

Power to the fuel injector 1 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E981]

A.

2.

No.

Readings

Fuel injector 1 test internal short or


disconnected

Resistance

At CN1, between (1) and (2)

0.4 - 1.1

Between CB3 (14) and CN1 (1)

Below 1

Between CB3 (24) and CN1 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 1 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN1 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (14) and (24)

Electrical circuit diagram related to fuel injector 1

20-434 1

PC400LC-7L

TROUBLESHOOTING

E982

12

E982
FUEL INJECTOR 2 DISCONNECTION

Fuel injector 2 circuit is disconnected. (Engine controller system)


Failure code ADB1KA.

Power to the fuel injector 2 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E982]

A.

2.

No.

Readings

Fuel injector 2 test internal short or


disconnected

Resistance

At CN2, between (1) and (2)

0.4 - 1.1

Between CB3 (6) and CN2 (1)

Below 1

Between CB3 (16) and CN2 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 2 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN2 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (6) and (16)

Electrical circuit diagram related to fuel injector 1

PC400LC-7L

20-435 1

TROUBLESHOOTING

E983

12

E983
FUEL INJECTOR 3 DISCONNECTION

Fuel injector 3 circuit is disconnected. (Engine controller system)


Failure code ADC1KA.

Power to the 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E983]

A.

2.

No.

Readings

Fuel injector 3 test internal short or


disconnected

Resistance

At CN3, between (1) and (2)

0.4 - 1.1

Between CB3 (5) and CN3 (1)

Below 1

Between CB3 (15) and CN3 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 3 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN3 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (5) and (15)

Electrical circuit diagram related to fuel injector 1

20-436 1

PC400LC-7L

TROUBLESHOOTING

E984

12

E984
FUEL INJECTOR 4 DISCONNECTION

Fuel injector 4 circuit is disconnected. (Engine controller system)


Failure code ADD1KA.

Power to the fuel injector 4 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E984]

A.

2.

No.

Readings

Fuel injector 4 test internal short or


disconnected

Resistance

At CN4, between (1) and (2)

0.4 - 1.1

Between CB3 (26) and CN4 (1)

Below 1

Between CB3 (36) and CN4 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 4 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN4 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (26) and (36)

Electrical circuit diagram related to fuel injector 1

PC400LC-7L

20-437 1

TROUBLESHOOTING

E985

12

E985
FUEL INJECTOR 5 DISCONNECTION

Fuel injector 5 circuit is disconnected. (Engine controller system)


Failure code ADE1KA.

Power to the fuel injector 5 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E985]

A.

2.

No.

Readings

Fuel injector 5 test internal short or


disconnected

Resistance

At CN5, between (1) and (2)

0.4 - 1.1

Between CB3 (33) and CN5 (1)

Below 1

Between CB3 (34) and CN5 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 5 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN5 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (34) and (3)

Electrical circuit diagram related to fuel injector 1

20-438 1

PC400LC-7L

TROUBLESHOOTING

E986

12

E986
FUEL INJECTOR 6 DISCONNECTION

Fuel injector 6 circuit is disconnected. (Engine controller system)


Failure code ADF1KA.

Power to the 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

---

Contents Of Trouble
Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E986]

A.

2.

No.

Readings

Fuel injector 6 test internal short or


disconnected

Resistance

At CN6, between (1) and (2)

0.4 - 1.1

Between CB3 (25) and CN6 (1)

Below 1

Between CB3 (35) and CN6 (2)

Below 1

0.4 - 1.1

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Fuel injector 6 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN6 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

Engine controller test

Resistance

At CB3, between (25) and (35)

Electrical circuit diagram related to fuel injector 1

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

---

Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E98A]

A.

2.

Readings

Fuel injector 1 test internal short or


disconnected

At CN1, between (1) and (2)


Resistance

At CN1, between (1) and (2) and grounding

0.4 - 1.1

Above 1M

Fuel injector 2 test internal short or


disconnected

At CN2, between (1) and (2)


Resistance

0.4 - 1.1

At CN2, between (1) and (2) and grounding

Above 1M

0.4 - 1.1

Above 1M

Fuel injector 3 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN3 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

4.

No.

Fuel injector 2 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN2 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

Specifications

Fuel injector 1 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN1 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Fuel injector 3 test internal short or


disconnected

At CN3, between (1) and (2)


Resistance

At CN3, between (1) and (2) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

A.

Wiring harness test


Contact with
grounding circuit

20-440 1

Resistance

Between CB3 (14) and CN1 (1) and grounding

Above 1M

Between CB3 (24) and CN1 (2) and grounding

Above 1M

Between CB3 (6) and CN2 (1) and grounding

Above 1M

Between CB3 (16) and CN2 (2) and grounding

Above 1M

10

Between CB3 (5) and CN3 (1) and grounding

Above 1M

11

Between CB3 (15) and CN3 (2) and grounding

Above 1M

12

PC400LC-7L

TROUBLESHOOTING
Steps
5.

Circuit Diagnostic Procedures For Code [E98A]

Specifications

No.

Between CB3 (14) and CN1 (1) and grounding

Below 1V

13

Between CB3 (24) and CN1 (2) and grounding

Below 1V

14

Between CB3 (6) and CN2 (1) and grounding

Below 1V

15

Between CB3 (16) and CN2 (2) and grounding

Below 1V

16

Between CB3 (5) and CN3 (1) and grounding

Below 1V

17

Between CB3 (15) and CN3 (2) and grounding

Below 1V

18

At CB3, between (14) and (24)

0.4 - 1.1

19

At CB3, between (6) and (16)

0.4 - 1.1

20

At CB3, between (5) and (15)

0.4 - 1.1

21

At CB3, between (5) and grounding

Above 1M

22

At CB3, between (6) and grounding

Above 1M

23

At CB3, between (14) and grounding

Above 1M

24

At CB3, between (15) and grounding

Above 1M

25

At CB3, between (16) and grounding

Above 1M

26

At CB3, between (24) and grounding

Above 1M

27

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the ON position during troubleshooting.

A.

6.

E98A

Wiring harness test


Contact with 24V
circuit

Voltage

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.

A.

Engine controller test

Resistance

Electrical circuit diagram related to fuel injectors 1, 2, and 3

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

---

Response from controller

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [E98B]

A.

2.

Readings

Fuel injector 4 test internal short or


disconnected

At CN4, between (1) and (2)


Resistance

At CN4, between (1) and (2) and grounding

0.4 - 1.1

Above 1M

Fuel injector 5 test internal short or


disconnected

At CN5, between (1) and (2)


Resistance

0.4 - 1.1

At CN5, between (1) and (2) and grounding

Above 1M

0.4 - 1.1

Above 1M

Fuel injector 6 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN6 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

4.

No.

Fuel injector 5 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN5 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

Specifications

Fuel injector 4 defective

Turn the engine ignition switch OFF for preparations.

Disconnect CN4 connection and install T-adapter.

Ignition switch OFF during troubleshooting.

Fuel injector 6 test internal short or


disconnected

At CN6, between (1) and (2)


Resistance

At CN6, between (1) and (2) and grounding

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.

A.

Wiring harness test


Contact with
grounding circuit

20-442 1

Resistance

Between CB3 (26) and CN4 (1) and grounding

Above 1M

Between CB3 (36) and CN4 (2) and grounding

Above 1M

Between CB3 (34) and CN5 (1) and grounding

Above 1M

Between CB3 (33) and CN5 (2) and grounding

Above 1M

10

Between CB3 (25) and CN6 (1) and grounding

Above 1M

11

Between CB3 (35) and CN6 (2) and grounding

Above 1M

12

PC400LC-7L

TROUBLESHOOTING
Steps
5.

Circuit Diagnostic Procedures For Code [E98B]

Specifications

No.

Between CB3 (26) and CN4 (1) and grounding

Below 1V

13

Between CB3 (36) and CN4 (2) and grounding

Below 1V

14

Between CB3 (34) and CN5 (1) and grounding

Below 1V

15

Between CB3 (33) and CN5 (2) and grounding

Below 1V

16

Between CB3 (25) and CN6 (1) and grounding

Below 1V

17

Between CB3 (35) and CN6 (2) and grounding

Below 1V

18

At CB3, between (26) and (36)

0.4 - 1.1

19

At CB3, between (34) and (33)

0.4 - 1.1

20

At CB3, between (25) and (35)

0.4 - 1.1

21

At CB3, between (25) and grounding

Above 1M

22

At CB3, between (26) and grounding

Above 1M

23

At CB3, between (33) and grounding

Above 1M

24

At CB3, between (34) and grounding

Above 1M

25

At CB3, between (35) and grounding

Above 1M

26

At CB3, between (364) and grounding

Above 1M

27

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapters.

Ignition switch should remain in the ON position during troubleshooting.

A.

6.

E98B

Wiring harness test


Contact with 24V
circuit

Voltage

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB3 and install T-adapter.

Ignition switch OFF during troubleshooting.

A.

Engine controller test

Resistance

Electrical circuit diagram related to fuel injectors 4, 5, and 6

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.

Engine high-idling speed out of standard


(Mechanical system)

If the machine is used as it is, the engine may be damaged.


Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)

Standard value in normal and references for troubleshooting

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.

Engine speed sensor system abnormal

3.

Engine controller defective

Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.
A.

Engine controller test

20-444 1

Engine speed

If error code E227 is displayed, carry out troubleshooting it first.

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

Engine low-idling speed out of standard


(Mechanical system)

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

If the machine is used as it is, the engine may be damaged.


Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)

Standard value in normal and references for troubleshooting

Cause

Engine mechanical system defective

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.

Engine speed sensor system abnormal

If error code E227 is displayed, carry out troubleshooting it first.

3.

Engine controller defective

Turn the engine ignition switch ON for preparations and keep the engine running during the troubleshooting.

1.

A.

Engine controller test

PC400LC-7L

Engine speed

Engine
Low idling

Monitoring
01006 Engine speed

975 1,025 rpm

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [AA10NX]

1.

Air cleaner clogged (While


Check the air cleaner. If it is clogged, clean or replace it.
system is normal)

2.

Air cleaner clogging switch defective

Turn the engine ignition switch OFF for preparations.

Disconnect A31 connection and install T-adapter.

Ignition switch OFF during troubleshooting.


A.

3.

Resistance

No.

At A31, between (1) and (2) - Normal

Below 1

At A31, between (1) and (2) - Clogged

Above 1M

Between P02 (5) and A31 (1)

Below 1

Between A31 (2) and grounding

Below 1

Between P02 (5) and grounding - Normal

Below 1V

Between P02 (5) and grounding - Clogged

20 - 30V

Readings

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

4.

Air cleaner clogging


switch test - internal
short or
disconnected

Specifications

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Monitor panel defective

Turn the ignition switch OFF for preparations.

Disconnect P02 and install T-adapter.

Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
A.

Monitor panel test

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [AB00KE]

Readings

Alternator test - internal short or


disconnected

At Alternator, between (terminal R) and grounding


Voltage

Above 20V

Below 1

If the voltage is abnormal, also check the belt tension.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Between P02 (11), J02 and Alternator terminal R

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

4.

No.

Wiring harness assembly

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Ignition switch should remain in the OFF position during troubleshooting.


A.

3.

Specifications

Alternator defective

Turn the engine ignition switch OFF for preparations.

Disconnect terminal R connection and install T-adapter.

Keep the engine running during troubleshooting.


A.

2.

Wiring harness test


Contact with
grounding circuit

Resistance

Between P02 (11), J02 and Alternator terminal R

Above 1M

Between P02 (11), D01, J01 and ignition switch terminal


BR

Above 1M

Between P02 (11), battery relay terminal BR and


grounding

Above 1M

Above 20V

Monitor panel defective

Turn the ignition switch OFF for preparations.

Disconnect P02 and install T-adapter.

Hold the ignition switch in the ON position or keep the engine running during the troubleshooting.
A.

Monitor panel test

20-448 1

Voltage

Between P02 (11) and grounding

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [B@BAZG]

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.

Engine oil pressure switch system defective

3.

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB1 and install T-adapters.

Hold ignition switch in the ON position or start engine during the troubleshooting.

Carry out troubleshooting for error code E936.

Engine
Stopped
A.

Engine controller test

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

TESTING AND ADJUSTING

B@BAZG

12
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)

PC400LC-7L

20-451

TESTING AND ADJUSTING

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [B@BAZK]

1.

Engine oil level low (While system is


normal)

2.

Engine oil level switch

Turn the engine ignition switch OFF for the preparations.

Hold ignition switch in the OFF position during troubleshooting.


A.

3.

Engine oil level


Resistance

No.

Readings

Normal level
Below normal level

OL

--Below 1

Above 1M

Below 1

Engine oil level - Normal

Below 1V

Engine oil level - Below normal

20 - 30V

Between (1) and ground

Wiring harness

Turn the engine ignition switch OFF for the preparations.

Disconnect P02 connector and install T-adapter.

Hold ignition switch in the OFF position during troubleshooting.


A.

4.

Engine oil level switch


defective
Internal disconnection

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.)

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Between P02 (8) and OL (1)

Monitor panel

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Hold ignition switch in the ON position or start engine during the troubleshooting.
A.

20-452

Monitor panel test

Voltage

Between P02 (8) and


grounding

PC400LC-7L

TESTING AND ADJUSTING

B@BAZK

12
Electrical circuit diagram related to engine oil level switch

PC400LC-7L

20-453

TESTING AND ADJUSTING

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [B@BCNS]

Specifications

No.

Readings

1.

Engine overheated (While system is


normal)

Check the engine for overheating. If it has been overheated, find out the cause and check the engine
for damage, then repair.

2.

Engine water high temperature sensor


system defective

Carry out troubleshooting for Display of engine water temperature gauge on monitor panel is
abnormal in E mode.

3.

Engine controller

With ignition switch in OFF position.

Disconnect engine controller CB2 and install T-adapters.

Hold ignition switch in the ON position or start engine during the troubleshooting.
A.

20-454

Engine controller test

Resistance

At CB2, between (27)


and (29)
At CB2, between (27)
and (39)

Engine water temperature


105C

3.28k

3.28k

PC400LC-7L

TESTING AND ADJUSTING

B@BCNS

12
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)

PC400LC-7L

20-455

TESTING AND ADJUSTING

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [B@BCZK]

1.

Sub-tank water level low (While system is


normal)

2.

Radiator water level switch

Turn the engine ignition switch OFF for the preparations.

Hold ignition switch in the OFF position during troubleshooting.


A.

3.

Sub-tank water level


Resistance

No.

Readings

Within normal level

A33

--Below 1

Above 1M

Between P02 (3) and A33 (1)

Below 1

Between A33 (2), J08, J12 and grounding

Below 1

Sub-tank water level - Within


normal

Below 1V

Sub-tank water level - Below


LOW level

20 - 30V

Below normal level

Between (1) and (2)

Wiring harness

Turn the engine ignition switch OFF for the preparations.

Disconnect P02 connector and install T-adapter.

Hold ignition switch in the OFF position during troubleshooting.


A.

4.

Radiator water level


switch defective
Internal disconnection

Specifications

Check the radiator sub-tank water level. If it is low, add water. (If it is reduced frequently, find out the
cause.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Monitor panel

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Hold ignition switch in the ON position or start engine during the troubleshooting.
A.

20-456

Monitor panel test

Voltage

Between P02 (3) and


grounding

PC400LC-7L

TESTING AND ADJUSTING

B@BCZK

Electrical circuit diagram related to radiator water level switch

PC400LC-7L

20-457

TESTING AND ADJUSTING

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.

Response from controller

None in particular.

Phenomenon occurring on
machine

If the machine is used as it is, the engine may be damaged.

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

Tools and Procedures

Digital Volt Ohm Meter.


T-adapter kit if appropriate.
Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [B@HANS]

1.

Hydraulic oil overheated (While system is


normal)

2.

Hydraulic oil temperature sensor

Turn the engine ignition switch OFF for the preparations.

Hold ignition switch in the OFF position during troubleshooting.


A.

3.

A61
Resistance

No.

Readings

Hydraulic oil temperature

Between (1) and (2)


Between (2) and
grounding

10 - 100C

--90 - 3.5k

Above 1M

Above 1M

90 - 3.5k

Above 1M

Wiring harness

Turn the engine ignition switch OFF for the preparations.

Disconnect P02 connector and install T-adapter.

Hold ignition switch in the OFF position during troubleshooting.


A.

4.

Hydraulic oil temperature sensor test


Internal disconnection

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.

Wiring harness test


Contact with
grounding circuit

Resistance

Between P02 (12) and A61 (2)

Monitor panel

With ignition switch in OFF position.

Disconnect engine controller P02 and install T-adapters.

Hold ignition switch in the ON position or start engine during the troubleshooting.
A.

20-458

Monitor panel test

Resistance

Between P02 (12) and


(13)
Hydraulic oil temperature
Between P02 (12) and 10 - 100C
grounding

PC400LC-7L

TESTING AND ADJUSTING

B@HANS

Electrical circuit diagram related to hydraulic oil temperature sensor

PC400LC-7L

20-459

TESTING AND ADJUSTING

B@HANS

12

MEMORANDUM

20-460

PC400LC-7L

TROUBLESHOOTING OF ELECTRICAL SYSTEM


(E MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF . . . . . . . . . . . . 20-504
USER CODE MEMORY RETENTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
THE ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
PREHEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
PREHEATING MONITOR DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
HEATER UNIT DOES NOT WARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
AUTO-DECELERATOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . 20-516
E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
ATTACHMENT CIRCUIT DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
NO DISPLAY IN MONITOR PANEL AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-525
E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
PART OF DISPLAY ON MONITOR PANEL IS MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-527
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL . . . . . . . . . . . . . . . . . . 20-527
E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-528
FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING . . . . . . . . . . . . . . 20-528
E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-529
E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-531
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . 20-531
E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
FUEL GAUGE DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-537
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED . . . . . . . . . . . . . . . . . . . . . . 20-537
E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539
WINDSHIELD WIPER DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-539

PC400LC-7L

20-501 1

TROUBLESHOOTING

TABLE OF CONTENTS

WINDSHIELD WASHER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-541


E-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
ALARM BUZZER CANNOT BE CANCELLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-543
E-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545
BOOM RAISE IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . 20-545
E-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-547
BOOM LOWER IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . 20-547
E-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-549
ARM IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-549
E-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
ARM DUMPING IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . 20-550
E-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
BUCKET CURL IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . 20-552
E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
BUCKET DUMPING IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . 20-553
E-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555
SWING IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION . . . . . . . . . . . . . . . . . . 20-555
E-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-557
TRAVEL IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . . 20-557
E-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
TRAVEL DIFFERENTIAL PRESSURE IS NOT CORRECTLY DISPLAYED IN MONITOR
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-559
E-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-561
SERVICE IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION . . . . . . . . . . . . . . . . . . . 20-561
E-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-563
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING . . . . . . . . . . . . . . . . . . . . 20-563
E-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . 20-565
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-565
E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 20-566
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-566
E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . 20-567
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . 20-567
E-32-E18 SHORT IN DAYLIGHT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E-32-E44 ABNORMALITY IN AIR MIX DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-569
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER . . . . . . . . . . . . . . 20-569
E-32 - TROUBLESHOOTING BY FAILURE PHENOMENON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-571

20-502 1

PC400LC-7L

TROUBLESHOOTING

BEFORE CARRYING OUT TROUBLESHOOTING

12

BEFORE CARRYING OUT TROUBLESHOOTING


CONNECTION TABLE OF FUSE BOX

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.

Type of power supply

Fuse No.

Fuse capacity

Destination of power
Pump controller (Controller power supply)

10 A

Swing holding brake solenoid (When emergency brake is released)


PC-EPC solenoid (When emergency pump is driven)
Pump controller (Solenoid power supply)

20 A

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Switch power supply


(Fusible link: A34)

Constant power
supply
(Fusible link: A35)

PC400LC-7L

Machine push-up solenoid


ATT return selector relay & solenoid
Starting motor cutout relay (For PPC lock)

10 A

10 A

10 A

Horn

10 A

(Spare)

10 A

Rotary lamp

10 A

Right front working lamp & boom working lamp

10 A

10

10 A

(Spare)

11

20 A

Air conditioner unit

12

20 A

13

20 A

14

10 A

15

10 A

16

10 A

Radio (For backing up)

17

10 A

Monitor panel (For backing up)

18

10 A

Starting switch

19

10 A

Room lamp

20

10 A

(Spare)

PPC lock solenoid


Cigarette lighter
Windshield washer motor

One-touch power maximizing switch (Input to pump controller input)


Radio

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

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM

12

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM


1.

Always turn power OFF before disconnecting or connecting connectors.

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.

When checking a single diode circuit:


Isolate the diode from the circuit.
using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
Electrical flow should be negative (-) to positive (+) only, red lead
positive and black lead negative.

6.

When checking a dual diode circuit:


Isolated the diode from the circuit.
using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
Electrical flow should be negative (-) to positive (+) only, red lead
positive and black lead negative.

7.

Always be aware of what you are measuring. Voltage, Ohms or Amps.


Always use caution when measuring a circuit.
When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are measuring.
When measuring ohms, be sure the circuit is dead and has no
voltage in it before you take any readings. Be sure the meter is set
in the proper ohms range.
When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage you equipment or possibly cause injury.
Always study the operators manuel for the meter you will be
using.

20-504 1

PC400LC-7L

TROUBLESHOOTING
12
POINTS

ITSELF

POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM

TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY

There is a high probability the same problem will occur again, it is desirable to follow up the problem carefully.
1.

If any abnormality returns to normal by itself.

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.

USER CODE MEMORY RETENTION FUNCTION


When displaying the codes in the memory and carrying out troubleshooting, record the content of the display first, then erase
the display. After re-enacting the problem, carry out troubleshooting according to the failure codes that are now displayed.
There are cases where mistaken operation or abnormalities occur when a connector is disconnected. Erasing the data in this
way saves any wasted work.

PC400LC-7L

20-505 1

TROUBLESHOOTING

INFORMATION CONTAINED IN TESTING PROCEDURES

12

INFORMATION CONTAINED IN TESTING PROCEDURES


The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.

Tools and Procedures

Contents Of Trouble

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information while
performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Service Code

What you
testing

are

4.

No.

Readings

Resistance
or
Voltage

Test procedure for component only.

readings

Your
information

Test procedure for component only.

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

At a diode, between point (x) and (x) reverse meter lead


polarity each time to check diode.

Continuity one
way only?

Yes or No

Wiring harness assembly test

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

Test procedure for harness. (connector) to (connector)

readings

Your
information

Test procedure for harness. (connector) to (connector)

readings

Your
information

B.Short to chassis ground or


within harness

Resistance
or
Voltage

Test procedure for harness. (connector) to (connector)

readings

Your
information

Test procedure for harness. (connector) to (connector)

readings

Your
information

Additional components to be tested

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

Test procedure for any additional components.

readings

Your
information

PC400LC-7L

TROUBLESHOOTING

INFORMATION CONTAINED IN TESTING PROCEDURES

12
Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.

Connector No.: Indicates (Type - numbers of a pin) (color)


Arrow: Roughly indicates the location in the machine where it is installed.

PC400LC-7L

20-507 1

TROUBLESHOOTING

E-1

12

E-1
THE ENGINE DOES NOT CRANK

The engine will not crank.


Failure code none displayed.

Relative information

The engine starting circuit has the start lock mechanism of the safety lock lever type

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

A.

Battery test
Insufficient capacity

Voltage
---

Battery voltage

Min. 24V

Min. 1.26

Fusible link A35

3.

Fuse No. 3 or 17

4.

Ignition switch

Prepare with ignition switch in the OFF position.

Disconnect H15 connector and install T-adapter.


A.

Ignition switch test


Internal disconnection

If circuit breaker is turned OFF or the fuse is broken, the circuit probably has a ground fault (See cause 9).

Resistance

At H15, between (1) and (4) key OFF position


At H15, between (1) and (4) key START position

Min. 1M

Max. 1

Safety lock switch test


Internal short circuit

Resistance

At S14, between (1) and (3), locked


At S14, between (1) and (3), unlocked

Min. 1M

Max. 1

Starting motor cut-out relays

Prepare with ignition switch in the OFF position.

Disconnect R11 and R13 connector and install T-adapter.

A.

7.

Readings

Safety lock switch

Prepare with ignition switch in the OFF position.

Disconnect S14 connector and install T-adapter.


A.

6.

No.

Electrolyte specific gravity

2.

5.

Specifications

Battery

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.

Starting motor cut-out


relays
Internal defect

Resistance

At R11, between (1) and (2)

100 - 500

At R11, between (3) and (5)

Min. 1M

At R11, between (3) and (6)

Max. 1

At R13, between (1) and (2)

100 - 500

At R13, between (3) and (5)

Min. 1M

10

At R13, between (3) and (6)

Max. 1

11

Starting motor

Prepare with ignition switch in the OFF position.

Turn ignition switch to START and carry out troubleshooting.

A.

Starting motor test


Internal defect

B - power supply

Starting motor, between terminal B


and chassis ground

20 - 30V

12

S - start

Starting motor, between ST (1) and


chassis ground

20 - 30V

13

R - charge

Starting motor, between ST (2) and


chassis ground

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).

Turn ignition switch ON and carry out troubleshooting.


A.

Alternator test
Internal short circuit

20-508 1

Voltage

Alternator, between terminal R and chassis ground

Max. 1V

15

PC400LC-7L

TROUBLESHOOTING
Steps
9.

E-1

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Wiring harness assembly test

With ignition switch in the OFF position.

Disconnect A35, H15, R1, R13, S14 connectors from and install T-adapter.

Carry out troubleshooting with ignition switch OFF.

Turn ignition switch ON during troubleshooting

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

Between battery relay terminal B and A35 (1)

Max. 1

16

Between A35 (2) and H15 (1)

Max. 1

17

Between H15 (4), J01 and R11 (5)

Max. 1

18

Between R11 (3) and ST (1)

Max. 1

19

Between FB1 (3) and S14 (1)

Max. 1

20

Between S14 (3) and R11 (1)

Max. 1

21

Between R11 (2) and R13 (6)

Max. 1

22

Between R13 (3), J04 and chassis ground

Max. 1

23

Between A35 (2) and H15 (1) and chassis ground

Min. 1M

24

Between H15 (4), J01 and R11 (5) and other related
circuits and chassis ground

Min. 1M

25

Between R11 (3) and ST (1) and chassis ground

Min. 1M

26

Between FB1 (3) and S14 (1) and chassis ground

Min. 1M

27

Between A14 (3) and R11 (1) and chassis ground

Min. 1M

28

Between R11 (2) and R13 (6) and chassis ground

Min. 1M

29

Between R13 (2), J05, P02 (14 and other related circuits
and chassis ground

Min. 1M

30

Max. 1V

31

Between ST(2), alternator terminal R, J02, D01 (6)


and P02 (11) and chassis ground

20-509 1

TROUBLESHOOTING

E-1

Electrical circuit diagram for engine preheating, starting, charging

20-510 1

PC400LC-7L

TROUBLESHOOTING

E-2

12

E-2
PREHEATER DOES NOT OPERATE
PREHEATING MONITOR DOES NOT LIGHT
Failure information

Tools and Procedures

Relative information

The preheater does not operate.

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)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Ignition switch
defective

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

3.

1. When the starting switch is turned to the HEAT position, the preheating
monitor does not light up.

system

Wiring harness test


Disconnection
or
defective contact with
connector

Specifications

No.

Readings

If the preheater does not operate (the heater unit is not warmed), carry out troubleshooting

Resistance

Between P02 (18) and J02 (7)

Below 1

Below 1V

20 - 30V

Monitor panel

Prepare with ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Hold ignition switch in OFF position or HEAT position during troubleshooting.


A.

Monitor panel test

PC400LC-7L

Voltage

At P02, between Ignition switch - OFF


(18) and ground Ignition switch - HEAT

20-511 1

TROUBLESHOOTING
12
HEATER

E-2

UNIT DOES NOT WARM


2. When the starting switch is turned to the HEAT position, the heater
unit is not warmed.

The preheater does not operate.

Relative information

Check that the starting motor rotates normally.


(If the starting motor does not rotate, carry out troubleshooting in E-1 Engine does not crank.)

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

A.
2.

Readings

Ignition switch test


Internal disconnection

Resistance

At H15, between Ignition switch - OFF


(1) and (3)
Ignition switch - HEAT

Above 1M

Below 1

Heater relay test


Internal disconnection

Continuity and
Resistance

Ignition switch
OFF
HEAT

Heater relay

---

Between coil terminal and grounding

Continued

Between contact terminals

Below 1

Continued

Intake air heater

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

4.

No.

Heater relay

With ignition switch in the OFF position.

Disconnect H15 and install T-adapter.

Hold ignition switch in OFF position or HEAT position during troubleshooting.


A.

3.

Specifications

Ignition switch

With ignition switch in the OFF position.

Disconnect H15 and install T-adapter.

Hold ignition switch in OFF position or HEAT position during troubleshooting.

Intake air heater test


Internal disconnection

Continuity

Intake air heater, between terminals

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

Wiring harness test


Disconnection
or
defective contact with
connector

20-512 1

Resistance

Between H15 (3), J02, and heater relay terminal

Below 1

Between starting motor terminal B and heater relay

Below 1

Between heater relay and intake air heater

Below 1

Between air heater and engine

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 does not work.

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.

Tools and Procedures

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Engine cooling water temperature signal

Turn the ignition switch ON for the trouble shooting

A.

Engine cooling water


temperature
signal
fault

Monitor code
04107

Engine cooling water temperature (low temperature)

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.

Engine controller test

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

The auto-decelerator does not operate.

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.

---

Presumed cause and standard value

Cause

Standard value and references for testing


Monitoring code

Item

Normal display

Boom RAISE signal fault

01900
Pressure switch 1

Boom RAISE

Lever operation: ON
Lever NEUTRAL: OFF

Boom LOWER signal fault

01900
Pressure switch 1

Boom LOWER

Lever operation: ON
Lever NEUTRAL: OFF

Arm RETRACT signal


fault

01900
Pressure switch 1

Arm RETRACT

Lever operation: ON
Lever NEUTRAL: OFF

Arm EXTEND signal fault

01900
Pressure switch 1

Arm EXTEND

Lever operation: ON
Lever NEUTRAL: OFF

Bucket CURL signal fault

01901
Pressure switch 2

Bucket CURL

Lever operation: ON
Lever NEUTRAL: OFF

Bucket DUMPING signal


fault

01901
Pressure switch 2

Bucket DUMPING

Lever operation: ON
Lever NEUTRAL: OFF

Swing signal fault

01900
Pressure switch 1

Swing

Lever operation: ON
Lever NEUTRAL: OFF

Travel signal fault

01900
Pressure switch 1

Travel

Lever operation: ON
Lever NEUTRAL: OFF

Service signal fault

01901
Pressure switch 2

Service

Lever operation: ON
Lever NEUTRAL: OFF

10

Pump controller defective

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

Engine controller defective

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

---

Tools and Procedures

Failure information

All the work equipment, swing and travel do not move.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 9 fault

1.

Safety lock switch

With ignition switch in the OFF position.

Disconnect S14 and install T-adapter.

Hold ignition switch in OFF position.


A.

2.

Readings

Resistance

At S14, between Safety lock lever - Free


(1) and (2)
Safety lock lever - Lock

Below 1

Above 1M

PPC lock solenoid


Internal
disconnection, short circuit or
ground fault

At V08, between (1) and (2)

20 - 60

Resistance

At V08, between (1) and grounding

Above 1M

Above 1M
( Continuity)

Assembled type diode D01

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

4.

No.

PPC lock solenoid

With ignition switch in the OFF position.

Disconnect V08 and install T-adapter.

Hold ignition switch in OFF position.


A.

3.

Safety lock switch test


Internal disconnection

Specifications

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.

Assembled type diode


D01
Internal short

Resistance

At D01, between (4) and (8)

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

B.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

20-516 1

Between FB1 (3) outlet and S14 (1)

Below 1

Between S14 (2) and J02 - V01 (2)

Below 1

Between V08 (1) to J13 and ground

Below 1

Between FB1 (3) outlet and S14 (1) and grounding

Above 1M

Between S14 (2) to J02 - V01 (2) and grounding

Above 1M

10

Between S14 (2) and D01 (4) and grounding

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

Tools and Procedures

Relative information

One-touch power max. function does not operate

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)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 3 fault

1.

One touch power max. switch

With ignition switch in the OFF position.

Disconnect M23 and install T-adapter.

Hold ignition switch in OFF position.


A.

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

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

B.

3.

One touch power max.


switch test
Internal disconnection

Specifications

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 2B.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Between FB1 (9) outlet and M23 (1)

Wiring harness test


Contact with
grounding circuit

Between FB1 (9) outlet and M23 (1) and grounding

Min. 1M

Resistance

Between FB1 (9) outlet and other related circuit and


grounding

Min. 1M

Max. 1V

20 - 30V

Pump controller

With ignition switch in the OFF position.

Disconnect C01 and install T-adapter

Keep ignition switch to the ON position for this test.


A.

Pump controller test

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.

Tools and Procedures

Failure
information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

(1)The machine push-up function does not operate.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Machine push-up switch

With ignition switch in the OFF position.

Disconnect M38 and install T-adapter.

Hold ignition switch in OFF position.


Machine push-up switch
A.

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

Between M38 (2), J07 and V06 (2) and grounding

Below 1V

Between M38 (2) and D02 (3) and grounding

Below 1V

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the ON position for this test.


A.

Wiring harness test


Contact with
24V grounding circuit

20-520 1

Voltage

PC400LC-7L

TROUBLESHOOTING
12
MACHINE

E-7

PUSH-UP FUNCTION IS NOT TURNED OFF

Machine push-up function does not operate normally.

Relative information

When the machine push-up function is set in the low pressure position, the solenoid is turned ON.

Tools and Procedures

Failure information

(2)The machine push-up function is not turned OFF.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 2 fault

1.

Machine push-up switch

With ignition switch in the OFF position.

Disconnect M38 and install T-adapter.

Hold ignition switch in OFF position.

Specifications

No.

Readings

If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit. See Step 4B.

Machine push-up switch


A.

2.

Below 1

Above 1M

Machine push-up
solenoid
Internal
disconnection, short circuit or
ground fault

At V06, between (1) and (2)

20 - 60

Resistance

At V06, between (2) and grounding

Above 1M

Above 1M
( Continuity)

Assembled type diode D02

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

4.

Resistance

At
M38, Low pressure position
between (1) and
High pressure position
(2)

Machine push-up solenoid

With ignition switch in the OFF position.

Disconnect V06 and install T-adapter.

Hold ignition switch in OFF position.


A.

3.

Machine
push-up
switch test
Internal disconnection

Assembled type diode


D02
Internal short

Resistance

At D02, between (3) and (7)

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

B.

Wiring harness test


Disconnection
or
defective contact with
connector
Wiring harness test
Contact with
grounding circuit

PC400LC-7L

Resistance

Resistance

Between FB1 (2) outlet and M38 (1)

Below 1

Between M38 (2) and J07 - V06 (2)

Below 1

Between V06 (1) and ground

Below 1

Above 1M

Between M38 (2) to J07 - V06 (2) and grounding

Above 1M

10

Between M38 (2) and D02 (3) and grounding

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.

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

A.

2.

No.

Readings

Attachment
return
selection solenoid test
Internal disconnection

At V12, between (1) and (2)


Resistance

20 - 60

Above 1M

At R20, between (3) and (5)

Below 1

At R20, between (3) and (6)

Above 1M

At V12, between (2) and grounding

Attachment return selection relay

With ignition switch in the OFF position.

Disconnect V06 and install T-adapter.

Hold ignition switch in OFF position.


A.

3.

Specifications

Attachment return selection solenoid

With ignition switch in the OFF position.

Disconnect V12 and install T-adapter.

Hold ignition switch in OFF position.

Attachment
return
selection relay
Internal
disconnection, short
circuit or ground fault

Resistance

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.

Hold ignition switch in the ON position for this test


A.

B.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with 24V
grounding circuit

Voltage

20-524 1

Between J03 (8) and R20 (3)

Below 1

Between R20 (5) and V12 (2)

Below 1

Between C03 (3), (13), (23) and V12 (1)

Below 1

Between R20 (5) and V12 (2) and grounding

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

---

Tools and Procedures

Failure information

No display in monitor panel at all.


When the engine starting switch is turned ON, there appears no display at all in the monitor panel.

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 12 fault

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect P01 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

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.

Wiring harness test


Disconnection
or
defective contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

From P01 (1), (2) to J07 to FB1 (12)

Below 1

From P01 (6), (7) to J04 and grounding

Below 1

Above 1M

Starting Switch
At P01, between (1), (2) and ground
ON

20 - 30V

Starting
OFF

Below 1

Between P01 (1), (2) to J07 to FB1 (12) outlet or related


circuits and grounding

Monitor panel

With ignition switch in the OFF position.

Disconnect P01 and install T-adapter.

Keep ignition switch to the ON position for this test.


Voltage
A.

Monitor panel test


Resistance

20-526 1

switch

At P01, between (6), (7) and ground

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

Standard value in normalcy and references for troubleshooting

Turn the starting switch ON during the troubleshooting.


1 Monitor panel LCD fault

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.

Switching operation: [/] + [A] (push switches simultaneously.)

2 Monitor panel defective

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

Standard value in normalcy and references for troubleshooting

Turn the starting switch in ON during the troubleshooting (monitoring).


1.

Model code signal fault


(Internal failure)

Monitoring code

Item

Normal display

00200

Controller model code

PC400-a

If the display on the monitor panel is normal, troubleshoot Error Code [E217].
2.

Monitor panel defective

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)

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuel level lowered


(system in normal condition)

2.

Fuel level sensor

With ignition switch in the OFF position.

Disconnect A60 and install T-adapter.

Hold ignition switch in OFF position.

Specifications

No.

Readings

Check fuel level in fuel tank. If insufficient, refill fuel.

Fuel level
A.
3.

Resistance

At A60, between
(1) and
grounding

FULL (Upper limit)

Approximately
12

EMPTY (Lower limit)

85 - 110

Below 1

FULL (Upper limit)

Approximately
12

EMPTY (Lower limit)

85 - 110

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

4.

Fuel level sensor test


Internal disconnection

Wiring harness test


Contact with
grounding circuit

Resistance

Between P02 (2) and A60 (1)

Monitor panel

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Hold ignition switch in OFF position.


Fuel level
A.

Monitor panel test

Resistance

At A60, between
(2) and
grounding

Electrical Circuit Diagram for Fuel Level Sensor

PC400LC-7L

20-529 1

TROUBLESHOOTING

E-13

12

E-13
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY

Failure
information

Tools and Procedures

Relative
information

Engine water temperature gauge does not display


correctly

2.

While the engine water temperature is stabilized normally, the


temperature gauge rises up to the red range (H).

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Engine water high temperature sensor

With ignition switch in the OFF position.

Disconnect TWH and install T-adapter.

Turn ignition switch ON or keep the engine running during troubleshooting.


A.

2.

While the engine water temperature rises normally, the temperature


gauge does not rise above the white range (C).

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.

Engine water high


sensor test - Internal
disconnection, short
circuit, ground fault

Resistance

At TWH, between (1) and (2)

3.5k - 90k

At TWH, between (1) and grounding

Above 1M

At TWH, between (2) and grounding

Above 1M

Wiring harness

With ignition switch in the OFF position.

Disconnect CB2 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Hold ignition switch in the ON position during troubleshooting.


A.

B.

C.

3.

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Wiring harness test


Contact with 24V
circuit

Voltage

Between CB2 (27) and THW (1)

Below 1

Between CB2 (29) and THW (2)

Below 1

Between CB2 (39) and THW (2)

Below 1

Above 1M

Below 1V

Between CB2 (27) and TWH (1) and ground

Between CB2 (27) and TWH (1) and ground

Engine controller

With ignition switch in the OFF position.

Disconnect CB2 and install T-adapter.

Keep ignition switch to the OFF position for this test.

A.

4.

Wiring harness test


Disconnection or
contact with
connector

Engine controller test

Monitor panel

20-530 1

Resistance

At CB2, between (27) and (39)

3.5k - 90k

At CB2, between (29) and (39)

3.5k - 90k

10

At CB2, between (27) and grounding

Above 1M

11

At CB2, between (29) and grounding

Above 1M

12

At CB2, between (39) and grounding

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

Tools and Procedures

Relative information

Hydraulic oil temperature gauge does not display correctly

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)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Hydraulic oil temperature sensor

With ignition switch in the OFF position.

Disconnect A61 and install T-adapter.

Turn ignition switch OFF.


Engine cooling water
temperature
A.

2.

Hydraulic oil
temperature sensor test
Resistance
- Internal
disconnection, short
circuit, ground fault

At A61, between (1) and (2)

90 - 3.5k

Above 1M

Between P02 (12) and A61 (2)

Below 1

Between P02 (13) and A61 (1)

Below 1

Above 1M

Below 1V

At P02, between (12) and (13)

90 - 3.5k

At P02, between (12) and


ground

90 - 3.5k

10 - 100C

At A61, between
grounding

(2)

and

Wiring harness

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Hold ignition switch in the ON position during troubleshooting.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance Between P02 (12) and A61 (2) and ground

Wiring harness test


Contact with 24V
circuit

Voltage

Between P02 (12) and A61 (2) and ground

Monitor panel

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.


Engine cooling water
temperature
A.

Monitor panel test

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

Tools and Procedures

Relative information

Fuel gauge does not display correctly

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)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Fuel level sensor

With ignition switch in the OFF position.

Disconnect A60 and install T-adapter.

Turn ignition switch OFF during troubleshooting.


Fuel level
A.

2.

Fuel level sensor test Internal


Resistance
disconnection, short
circuit, ground fault

FULL (Upper limit)


EMPTY (Lower limit)

At A60, between
grounding

(1)

and

Approximately
12

85 - 110

Below 1

Above 1M

Below 1V

Approximately
12

85 - 110

Wiring harness

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Hold ignition switch in the ON position during troubleshooting.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance Between P02 (2) and A60 (1)

Wiring harness test


Contact with
grounding circuit

Resistance Between P02 (2) and A60 (1) and ground

Wiring harness test


Contact with 24V
circuit

Voltage

Between P02 (2) and A60 (1) and ground

Monitor panel

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.


Fuel level
A.

Monitor panel test

Resistance

FULL (Upper limit)


EMPTY (Lower limit)

20-534 1

At P01, between (2) and ground

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

Tools and Procedures

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)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Swing lock monitor does not display correctly

1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Swing lock switch

With ignition switch in the OFF position.

Disconnect X05 and install T-adapter.

Turn ignition switch OFF during troubleshooting.


Swing lock switch
A.

2.

Swing lock switch test


Internal
Resistance
disconnection, short
circuit, ground fault

OFF

Above 1M

Below 1

From P02 (17) to J02 and X05and A60 (1)

Below 1

From X05 (2) to J05 and grounding

Below 1

From P02 (17) to J02 to X05 (1) and ground

Above 1M

From P02 (17) to C02 (38) and ground

Above 1M

From P02 (17) to J02 and X05 (1) and ground

Below 1V

From P02 (17) to C02 (38) and ground

Below 1V

ON

At X05, between (1) and (2)

Wiring harness

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Hold ignition switch in the ON position during troubleshooting.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Wiring harness test


Contact with 24V
circuit

Voltage

Monitor panel

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.


Swing lock switch
A.

Monitor panel test

20-536 1

Voltage

OFF
ON

At P01, between (17) and


ground

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

When monitor switch is operated, nothing is


displayed.

Relative information

---

Presumed cause and


standard value in
normalcy

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(2) When LCD monitor adjustment switch is operated, mode selection screen is
not displayed.

Relative information

---

Presumed cause and


standard value in
normalcy

Cause

(1) When mode selector switch is operated, working mode monitor is not
displayed.

Cause

Standard value in normalcy and references for troubleshooting

Standard value in normalcy and references for troubleshooting

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(3) When selector switch is operated, flow rate adjustment screen or flow rate
selection screen is not displayed.

Relative information

---

Presumed cause and


standard value in
normalcy

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(4) When maintenance switch is operated, item selection screen is not displayed.

Relative information

---

Presumed cause and


standard value in
normalcy

Cause

Cause

Standard value in normalcy and references for troubleshooting

Standard value in normalcy and references for troubleshooting

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(5) When automatic deceleration switch is operated, automatic deceleration


monitor is not displayed.

Relative information

When the automatic decelerator does not operate either, conduct the troubleshooting for E-4.

Presumed cause and


standard value in
normalcy

Cause

Standard value in normalcy and references for troubleshooting

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(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.

Presumed cause and


standard value in
normalcy

Monitor panel defective

As this is an internal failure, troubleshooting cannot be conducted.

Failure information

When monitor switch is operated, nothing is


displayed.

(7) When wiper switch is operated, wiper monitor is not displayed.

Relative information

When the wiper does not operate either, conduct the troubleshooting for E-18.

Presumed cause and


standard value in
normalcy

20-538 1

Cause

Cause
Monitor panel defective

Standard value in normalcy and references for troubleshooting

Standard value in normalcy and references for troubleshooting


As this is an internal failure, troubleshooting cannot be conducted.

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

Tools and Procedures

Relative information

Windshield wiper and window washer do not work.

Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

(1) The windshield wiper does not work.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Window rear limit switch

With ignition switch in the OFF position.

Disconnect W03 and install T-adapter.

Turn ignition switch OFF during troubleshooting.


Front window
A.

2.

Above 1M

Below 1

Continued

From P01 (9) and W04 (3)

Below 1

From P01 (10) and W04 (1)

Below 1

Above 1M

20 - 30V

Below 1V

When retracted at rear

At W03, between (1) and (2)

Windshield
wiper Continuity
motor test - Internal and resistance value
disconnection

At W04, between (3) and (1)

Wiring harness

With ignition switch in the OFF position.

Disconnect P01 and P02 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

B.

4.

When installed at front

Windshield wiper motor

With ignition switch in the OFF position.

Disconnect W03 and install T-adapter.

Turn ignition switch OFF or keep the engine running during troubleshooting.
A.

3.

Window rear limit


switch test - Internal
Resistance
disconnection, short
circuit, ground fault

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance From P02 (15) and W03 (2)

Monitor panel (Window rear limit switch system)

Turn the engine ignition switch OFF for preparations.

Disconnect P02 and install T-adapter.

Hold ignition switch in the ON position during the troubleshooting.


Front window
A.

5.

Monitor panel
(Window rear limit
switch system) test

When installed at front


Voltage

When retracted at rear

At P02, between (15) and


ground

Monitor panel (Windshield wiper motor system)

With ignition switch in the OFF position.

Disconnect P01 and install T-adapter.

Keep ignition switch to the ON position for this test.


Windshield wiper switch
A.

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

WASHER DOES NOT OPERATE


Windshield wiper and window washer do not work.

Relative information

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 4

2.

Windshield wiper motor

With ignition switch in the OFF position.

Disconnect A50 and install T-adapter.

Turn ignition switch OFF or keep the engine running during troubleshooting.
A.

3.

(2) Windshield washer does not operate.

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

From FB1 (4) to J03 to J06 and A50 (1)

Below 1

From FB1 (4) to J04 and P01 (3)

Below 1

Above 1M

Above 1M

Above 1M

Above 1M

Wiring harness

With ignition switch in the OFF position.

Disconnect A50 and P01 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

Wiring harness test


Disconnection or
contact with
connector

Resistance

From FB1 (4) to J03 to J06 A50 (1) and grounding


B.

Wiring harness test


Contact with
grounding circuit

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

With ignition switch in the OFF position.

Disconnect P01 and install T-adapter.

Keep ignition switch to the ON position for this test.


Windshield wiper switch
A.

Monitor panel test

20-542 1

Voltage

OFF
ON

At P01, between (3) and ground

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

The 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)

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Alarm buzzer stop switch

With ignition switch in the OFF position.

Disconnect P03 and install T-adapter.

Turn ignition switch OFF.


Alarm buzzer stop switch
A.

2.

Release

Above 1M

Depress

Below 1

At P02 (16) and P03 (1)

Below 1

From P03 (2) to J05 to grounding

Below 1

Between P02 (16) and P03 (1) and grounding

Below 1V

20 - 30V

Below 1V

Alarm buzzer stop


At P03, between (1) and
switch test - Internal Resistance
(2)
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect P01, P02 and P03 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Voltage

Monitor panel

With ignition switch in the OFF position.

Disconnect P02 and install T-adapter.

Keep ignition switch to the ON position for this test.


Alarm buzzer stop switch
A.

Monitor panel test

20-544 1

Voltage

Release
Depress

At P02, between (16) and


ground

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Boom Raise is not correctly displayed in monitor function


Boom Raise is not correctly displayed in the monitor function on the monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Boom RAISE PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S06 and install T-adapter.

Keep the engine running during troubleshooting.


RH work equipment control
lever
A.

2.

NEUTRAL

Above 1M

Boom RAISE

Below 1

Between C03 (10) and S06 (2)

Below 1

Boom RAISE PPC


At S06, between (1) and
hydraulic switch test - Resistance
(2)
Internal disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03 and S06 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Between S06 (1) and grounding

Below 1

Wiring harness test


Contact with
grounding circuit

Resistance Between C03 (10) and S06 (2) and grounding

Above 1M

Below 1V

20 - 30V

Below 1V

Wiring harness test


Contact with 24V
circuit

Voltage

Between C03 (10) and S06 (2) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during troubleshooting.


RH work equipment
control lever
A.

Pump controller test

20-546 1

Voltage

NEUTRAL
Boom RAISE

At C03, between (10) and


ground

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Boom LOWER is not correctly displayed in monitor function


Boom LOWER is not correctly displayed in the monitor function on the monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Boom LOWER PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S02 and install T-adapter.

Keep the engine running during troubleshooting.


RH work equipment control
lever
A.

2.

NEUTRAL

Above 1M

Boom LOWER

Below 1

Between C03 (20) and S02 (2)

Below 1

Boom LOWER PPC


At S02, between (1) and
hydraulic switch test - Resistance
(2)
Internal disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03 and S02 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Between S02 (1) and grounding

Below 1

Wiring harness test


Contact with
grounding circuit

Resistance Between C03 (20) and S02 (2) and grounding

Above 1M

Below 1V

20 - 30V

Below 1V

Wiring harness test


Contact with 24V
circuit

Voltage

Between C03 (20) and S02 (2) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


RH work equipment
control lever
A.

Pump controller test

20-548 1

Voltage

NEUTRAL
Boom LOWER

At C03, between (20) and


ground

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

---

Arm IN is not displayed normally in monitoring


function.

Cause

Arm IN is not displayed normally in monitoring function (special


function) of monitor panel.

Standard value in normalcy and references for troubleshooting

1.

Arm IN PPC pressure sensor defective

The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for error code [E247].

2.

Pump controller defective

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Arm DUMPING is not correctly displayed in monitor function


Arm DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Arm DUMPING PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S08 and install T-adapter.

Keep the engine running during troubleshooting.


LH work equipment control
lever
A.

2.

NEUTRAL

Above 1M

Arm DUMPING

Below 1

Between C03 (40) and S08 (2)

Below 1

Arm DUMPING PPC


At S08, between (1) and
hydraulic switch test - Resistance
(2)
Internal disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03 and S08 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Between S08 (1) and grounding

Below 1

Wiring harness test


Contact with
grounding circuit

Resistance Between C03 (40) and S08 (2) and grounding

Above 1M

Below 1V

20 - 30V

Below 1V

Wiring harness test


Contact with 24V
circuit

Voltage

Between C03 (40) and S08 (2) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


LH work equipment
control lever
A.

Pump controller test

PC400LC-7L

Voltage

NEUTRAL
Arm DUMPING

At C03, between (40) and


ground

20-551 1

TROUBLESHOOTING

E-23

Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch

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

Standard value in normalcy and references for troubleshooting

1.

Bucket CURL PPC pressure sensor


The bucket CURL PPC pressure sensor may be defective. Carry out troubleshooting for error code [E248].
defective

2.

Pump controller defective

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Bucket DUMPING is not correctly displayed in monitor function.


Bucket DUMPING is not correctly displayed in the monitor function (special function) on the monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Bucket DUMPING PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S05 and install T-adapter.

Keep the engine running during troubleshooting.


RH work equipment control
lever
A.

2.

NEUTRAL

Above 1M

Bucket DUMPING

Below 1

Between C03 (19) and S05 (2)

Below 1

Bucket
DUMPING
At S05, between (1) and
PPC hydraulic switch
Resistance
(2)
test - Internal
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03 and S05 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Between S05 (1) and grounding

Below 1

Wiring harness test


Contact with
grounding circuit

Resistance Between C03 (19) and S05 (2) and grounding

Above 1M

Below 1V

20 - 30V

Below 1V

Wiring harness test


Contact with 24V
circuit

Voltage

Between C03 (19) and S05 (2) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


RH work equipment
control lever
A.

Pump controller test

20-554 1

Voltage

NEUTRAL
Bucket DUMPING

At C03, between (19) and


ground

PC400LC-7L

TROUBLESHOOTING

E-25

Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Swing is not displayed normally in monitoring function (special


function) of monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Swing left PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S07 and install T-adapter.

Keep the engine running during troubleshooting.


LH work equipment control
lever
A.

2.

Swing
left
PPC
At S07, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection

NEUTRAL

Min. 1M

Left swing position

Max. 1

NEUTRAL

Min. 1M

Right swing position

Max. 1

Swing right PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S03 and install T-adapter.

Keep the engine running during troubleshooting.


RH work equipment control
lever
A.

3.

Swing
right
PPC
At S03, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03, S07 and S03 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

4.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Wiring harness test


Contact with 24V
circuit

Voltage

Between C03 (29) and S07 (2)

Max. 1

Between C03 (29) and S03 (2)

Max. 1

Between S07(1) and grounding

Max. 1

Between S07(1) and grounding

Max. 1

Between C03 (29) and S07 (2) and grounding

Min. 1M

Between C03 (29) and S07 (2) and grounding

Min. 1M

10

Between C03 (29) and S07 (2) and grounding

Max. 1V

11

Between C03 (29) and S03 (2) and grounding

Max. 1V

12

20 - 30V

13

Max. 1V

14

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Keep the engine running during the troubleshooting.


LH work equipment
control lever
NEUTRAL
A.

Pump controller test

20-556 1

Voltage

Left or right swing


position

At C03, between (29) and


ground

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Travel PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S30 and install T-adapter.

Keep the engine running during troubleshooting.


Travel control lever
A.

2.

NEUTRAL

Above 1M

Forward or reverse

Below 1

From C03 (39) to J01 to S30 (2)

Below 1

From S30 (1) to J05 to grounding

Below 1

From C03 (39) to J01 to S30 (2) and grounding

Above 1M

From C03 (39) to A43 (2) and grounding

Above 1M

From C03 (39) to J01 to S30 (2) and grounding

Below 1V

From C03 (39) and A43 (2) and grounding

Below 1V

Travel PPC hydraulic


At S30, between (1) and
switch test - Internal
Resistance
(2)
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C03 and S30 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance

Wiring harness test


Contact with 24V
circuit

Voltage

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Keep the engine running during the troubleshooting.


Travel control lever
A.

Pump controller test

20-558 1

Voltage

NEUTRAL
Forward or backward

At C03, between (39) and


ground

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

Travel Differential Pressure is not correctly displayed in monitor function


Travel Differential Pressure is not correctly displayed in the monitor function (special function) on the monitor panel.

Relative information

When pressure difference is created between the right and left travel PPC circuits (in steering), the travel differential
mechanism is turned ON.

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Travel steering PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S31 and install T-adapter.

Keep the engine running during troubleshooting.


Travel control lever
A.

2.

NEUTRAL

Above 1M

One side of right or left only

Below 1

Between C02 (16) and S31 (2)

Below 1

From S31 (1) to J05 to grounding

Below 1

Above 1M

Below 1V

20 - 30V

Below 1V

Travel steering PPC


At S31, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C02 and S31 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

3.

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Resistance Between C02 (16) and S31 (2) and grounding

Wiring harness test


Contact with 24V
circuit

Voltage

From C02 (16) and S31 (2) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


Travel control lever
NEUTRAL
A.

Pump controller test

20-560 1

Voltage

One side of right or left


only

At C03, between (39) and


ground

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

---

Tools and Procedures

Failure information

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps
1.

Service is not correctly displayed in monitor function.


Service is not correctly displayed in the monitor function (special function) on the monitor panel.

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Service (front) PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S10 and install T-adapter.

Keep the engine running during troubleshooting.


Service pedal
A.

2.

Service (front) PPC


At S10, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection

NEUTRAL

Above 1M

Operated to front

Below 1

NEUTRAL

Above 1M

Operated to rear

Below 1

Service (rear) PPC hydraulic switch

With ignition switch in the OFF position.

Disconnect S11 and install T-adapter.

Keep the engine running during troubleshooting.


Service pedal
A.

3.

Service (rear) PPC


At S10, between (1) and
hydraulic switch test Resistance
(2)
Internal
disconnection

Wiring harness

With ignition switch in the OFF position.

Disconnect C02, S10 and S11 and install T-adapter.

Keep ignition switch to the OFF position for this test.

Have ignition switch ON for this test.


A.

B.

C.

4.

Wiring harness test


Disconnection or
contact with
connector

Between C02 (35) and S10 (2)

Below 1

Resistance Between C02 (35) and S11 (2)

Below 1

Below 1

Wiring harness test


Contact with
grounding circuit

Between C02 (35) and S10 (2) and grounding

Above 1M

Resistance

Between C02 (35) and S11 (2) and grounding

Above 1M

Wiring harness test


Contact with 24V
circuit

Between C02 (35) and S10 (2) and grounding

Below 1V

10

Voltage

Between C02 (35) and S11 (2) and grounding

Below 1V

11

Between S10 (1) and grounding

Pump controller

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


Service pedal
A.

Pump controller test

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

Tools and Procedures

Relative information

Travel alarm does not sound or does not stop sounding.

1.

The travel alarm does not sound while the machine is traveling.

2.

The alarm begins to sound when the machine is at a standstill.

---

Digital Volt Ohm Meter. T-adapter kit.


Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse No. 15

2.

Travel signal

Start the engine during troubleshooting (monitoring).


A.

3.

No.

Readings

Monitoring code
01900

Item

Normal display

Travel

Control lever operated: ON


Control lever NEUTRAL: OFF

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

B.

4.

Travel signal test Internal


disconnection

Specifications

When fuse No. 15 is blown, there is a big possibility that ground fault occurred in the circuit. (See Step 3B.)

Between FB1 (15) outlet to J03 and A43 (1)

Below 1

Between A43 (2) and J01 (19)

Below 1

Above 1M

Above 1M

Wiring harness test


Disconnection or
contact with
connector

Resistance

Wiring harness test


Contact with
grounding circuit

Between FB1 (15) outlet to J03 and A43 and grounding


Resistance Between FB1 (15) outlet and other related circuit and
grounding

Travel alarm

With ignition switch in the OFF position.

Disconnect C03 and install T-adapter.

Start the engine during the troubleshooting.


A.

Travel alarm test

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.

TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE


Self-diagnosis notice

Failure mode

E--

No failures

E11

Disconnection in recirculated air sensor

E12

Short-circuit in recirculated air sensor

E15

Disconnection in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in daylight sensor

E43

Abnormality in air outlet damper

E44

Abnormality in air mix damper

E45

Abnormality in recirculated and fresh air damper

Check the Self-diagnosis notice on the control panel according to the following procedure.

How to display Self-diagnosis notice

1.

Turn the starting switch ON.

2.

Press OFF switch (1) and check that anything is not displayed on
display monitor (2).

3.

4.

Hold the UP switch () and DOWN switch () of temperature setting


switch (3) simultaneously for 3 seconds or more.
Check the Self-diagnosis notice displayed on display monitor (2).
How to select Self-diagnosis notice
If multiple Self-diagnosis notices are recorded, press the UP switch
() or DOWN switch () of temperature setting switch (3) to select
another notice.
How to delete Self-diagnosis notice
When reproducing the Self-diagnosis notices or after removing the cause of a failure, press the switches on both sides of
recirc/fresh air selector switch (4) simultaneously for 3 seconds or more, and all the Self-diagnosis notices are deleted.
Finishing display of Self-diagnosis notice
To finish display of the Self-diagnosis notice, press OFF switch (1) or turn the starting switch OFF.

20-566 1

PC400LC-7L

TROUBLESHOOTING
12
E-32-E11

DISCONNECTION IN RECIRCULATED AIR SENSOR

Self-diagnosis notice

Trouble

E11
Contents of trouble

Action of control panel

Related information

Disconnection in the recirculated air sensor system is detected.

Fixes the recirculated air temperature 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>

--Circuit Diagnostic Procedures For Code [---]

No.

Readings

Recirculation air
sensor test - Internal
disconnection

Resistance At THi, between (1) and (2)

300 430k

Between M30 (12) and THi (2)

Max. 1

Between M29 (11) and THi (1)

Max. 1

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

3.

Specifications

Recirculated air sensor

Prepare with the ignition switch OFF

Disconnect THi connection and install T-adapter.

Keep the ignition switch in the OFF position for troubleshooting.


A.

2.

Disconnection in recirculated air sensor

Steps
1.

E-32

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

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.

E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE


Self-diagnosis

Trouble

E12
Contents of trouble

Action of control panel

Related information

Short circuit in the recirculated air sensor system is detected.

Fixes the recirculated air temperature 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.

Circuit Diagnostic Procedures For Code [---]

No.

Readings

Recirculation air
sensor test - Internal
disconnection

Resistance At THi, between (1) and (2)

300 430k

Between M30 (12) and THi (2)

Max. 1

Between M29 (11) and THi (1)

Max. 1

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

3.

Specifications

Recirculated air sensor

Prepare with the ignition switch OFF

Disconnect THi connection and install T-adapter.

Keep the ignition switch in the OFF position for troubleshooting.


A.

2.

Short circuit in recirculated air sensor

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

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

DISCONNECTION IN WATER TEMPERATURE SENSOR

Self-diagnosis notice

Trouble

E15
Contents of trouble

Action of control panel

Related information

Disconnection in water temperature sensor

Disconnection in the water temperature sensor system is detected.

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

Circuit Diagnostic Procedures For Code [---]

Specifications

No.

Readings

Water temperature sensor

Prepare with the ignition switch OFF

Disconnect THw connection and install T-adapter.

Keep the ignition switch in the OFF position for troubleshooting.


A.

2.

Water temperature
sensor test - Internal
disconnection

Resistance At THw, between (1) and (2)

95 455k

Between M30 (14) and THw (2)

Max. 1

Between M29 (11) and THw (1)

Max. 1

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

3.

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

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.

E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR


Self-diagnosis notice

Trouble

E16
Contents of trouble

Action of control panel

Related information

Short circuit in the water temperature sensor system is detected.

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.

Circuit Diagnostic Procedures For Code [---]

No.

Readings

Water temperature
sensor test - Internal
disconnection

Resistance At THw, between (1) and (2)

95 455k

Between M30 (14) and THw (2)

Max. 1

Between M29 (11) and THw (1)

Max. 1

Wiring harness

With ignition switch in the OFF position.

Keep ignition switch to the OFF position for this test.


A.

3.

Specifications

Water temperature sensor

Prepare with the ignition switch OFF

Disconnect THw connection and install T-adapter.

Keep the ignition switch in the OFF position for troubleshooting.


A.

2.

Short circuit in water temperature sensor

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

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

SHORT IN DAYLIGHT SENSOR

Self-diagnosis notice

Trouble

E18
Contents of trouble

Action of control panel

Related information

Short circuit in daylight sensor

Short circuit in the daylight sensor system is detected.

Assumes that the daylight sensor is not installed 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

Circuit Diagnostic Procedures For Code [---]

1.

Daylight sensor

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect M30 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

3.

Specifications

No.

Readings

The daylight sensor may be defective. Check it directly

Wiring harness test


Disconnection or
contact with
connector

Resistance

Between M30 (16) and P15 (2)

Max. 1

Between M30 (3) and P15 (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.

Air conditioner system

E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER


Self-diagnosis notice

Trouble

E43
Contents of trouble

Action of control panel

Related information
Steps

Trouble Abnormality in air outlet damper

Abnormality in air outlet servomotor system is detected.

Stops the air outlet servomotor.


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>

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.

Air outlet servo motor

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect Mv1, M29 and M30 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

3.

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

PC400LC-7L

Specifications

No.

Readings

The air outlet servo motor may be defective. Check it directly

Between Mv1 (1) and M30 (3)

Max. 1

Between Mv1 (3) and M29 (11)

Max. 1

Resistance Between Mv1 (5) and M30 (9)

Max. 1

Between Mv1 (6) and M29 (8)

Max. 1

Between Mv1 (7) and M29 (9)

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

ABNORMALITY IN AIR MIX DAMPER

Self-diagnosis notice

Trouble

E44
Contents of trouble

Action of control panel

Related information

Abnormality in air mix damper

Abnormality in air mix servomotor system is detected.

Stops the air mix servomotor.


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>

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

Circuit Diagnostic Procedures For Code [---]

1.

Air mix servo motor

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect Mam, M29 and M30 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

3.

Specifications

No.

Readings

The air mix servo motor may be defective. Check it directly

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

Between Mam (1) and M29 (11)

Max. 1

Between Mam (3) and M30 (3)

Max. 1

Resistance Between Mam (5) and M30 (2)

Max. 1

Between Mam (6) and M29 (4)

Max. 1

Between Mam (7) and M29 (5)

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.

E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER


Self-diagnosis notice

Trouble

E45
Contents of trouble

Action of control panel

Related information

Abnormality in recirculated and fresh air servomotor system is detected.

Stops the recirculated and fresh air servomotor.


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>

Do not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage the motor output

Steps
1.

Abnormality in recirculated and fresh air damper

shaft and break the motor coils.


Circuit Diagnostic Procedures For Code [---]

2.

Fuse (in unit)

3.

Wiring harness

With ignition switch in the OFF position.

Disconnect Mrf, M29 and M33 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

4.

Specifications

No.

Readings

Recirculated and fresh air


The recirculated and fresh air servo motor may be defective. Check it directly
servo motor

Wiring harness test


Disconnection or
contact with
connector

Air conditioner system

20-570 1

If the fuse (in unit) is broken, the circuit probably has a ground fault, etc. Check the related circuits.

Between Mrf (1) and M29 (6)

Max. 1

Resistance Between Mrf (3) and M29 (7)

Max. 1

Between Mrf (7) and M33 (3)

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

- TROUBLESHOOTING BY FAILURE PHENOMENON

Trouble

Related information

---

Steps

The air conditioner does not operate.

Fuse No. 11

2.

Wiring harness

With ignition switch in the OFF position.

Disconnect M27, M29 and M30 and install T-adapter.

Keep ignition switch to the OFF position for this test.


A.

B.

Wiring harness test


Disconnection or
contact with
connector

Specifications

No.

Readings

If the fuse is broken, the circuit probably has a ground fault, etc. Refer to cause 3.

Resistance

Between fuse (11) and M33 (3)

Max. 1

Between M27 (14) and M30 (6)

Max. 1

Between M33 (2) and chassis ground

Max. 1

Between M29 (12) and chassis ground

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

Air conditioner unit

With ignition switch in the OFF position.

Disconnect M33 and install T-adapter.

Turn ignition switch to the ON position for this test.


A.

4.

The air conditioner does not operate at all.

Circuit Diagnostic Procedures For Code [---]

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

With ignition switch in the OFF position.

Disconnect M33 and M29 and install T-adapter.

Turn ignition switch to the ON position for this test.


A.

Control panel test

Voltage

Between M30 (6) and M29 (12)

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

The air conditioner does not operate.

2.

Air does not come out (Air flow is insufficient).

Related information
Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse (in unit)

2.

Blower relay

Prepare with ignition switch OFF.

Disconnect connector R30 and install T-adapter.

Keep ignition switch OFF.


A.

3.

Readings

Blower relay (on coil


Resistance At R30, between (1) and (3)
side) test

140 - 340

Blower relay (on


contact side) test

Voltage

At R30, between (4) and ground

20 - 30V

Power transistor

Prepare with ignition switch OFF.

Turn ignition switch ON and carry out troubleshooting.


A.

5.

No.

Blower relay

Prepare with ignition switch OFF.

Disconnect connector R30 and install T-adapter.

Keep ignition switch OFF.


A.

4.

Specifications

If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.

Power transistor test

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

Prepare with ignition switch OFF.

Disconnect connector NB and install T-adapter.

Turn ignition switch ON and carry out troubleshooting.


A.

Blower motor test

Fan switch
Voltage

ON

At MB, between (1) and (2)

20 - 30V

If the above voltage is normal and the blower motor does not rotate, the blower motor is defective.
6.

Wiring harness

Prepare with ignition switch in the OFF position.

Disconnect R30, R31, Mb, Ptr, M27, M29 and M30 and install T-adapters.

Keep ignition switch to the OFF position for this test.


Between fuse 11 outlet, fuse in unit, R30 (3), R31 (1) and
M30 (6)
A.

7.

Wiring harness test


Disconnection or
contact with
connector

Air conditioner unit

PC400LC-7L

Max. 1

Between M29 (3) and R30 (1)

Max. 1

Between M29 (12) and chassis ground

Max. 1

Resistance Between Mb (1) and R30 (4)


Between Mb (2) and Ptr (3)

Max. 1

Max. 1

9
10

Between Ptr (1) and chassis ground

Max. 1

Between Ptr (2) and M30 (7)

Max. 1

11

Between Ptr (4) and M30 (8)

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

The air conditioner does not operate.

3.

Air is not cooled (Cooling capacity is low).

Related information
Steps

Circuit Diagnostic Procedures For Code [---]

1.

Fuse (in unit)

2.

Compressor relay

Prepare with ignition switch OFF.

Disconnect connector R31 and install T-adapter.

Keep ignition switch OFF.


A.

3.

Specifications

No.

Compressor relay (on


Resistance At R31, between (1) and (2)
coil side) test

140 - 340

Compressor relay

Prepare with ignition switch OFF.

Disconnect connector R31 and install T-adapter.

Turn ignition switch ON and carry out troubleshooting (Setting of temperature: Highest cooling position).
A.

Compressor relay (on


contact side) test

Voltage

At R31, between (4) and ground (Fan switch ON)

4.

Thermostat (Internal defect)

5.

High/Low pressure switch

Prepare with ignition switch OFF.

Disconnect connector P17 and install T-adapter.

Keep ignition switch OFF and carry out troubleshooting.


A.

High/Low
switch test

pressure

20 - 30V

The thermostat may be defective. Check it directly.

Resistance At P17, between (1) and (2)

2
3

Max. 1

6.

Compressor clutch

The compressor clutch may be defective. Check it directly.

7.

Compressor

The compressor may be defective. Check it directly.

8.

Wiring harness

Prepare with ignition switch in the OFF position.

Disconnect M30, M29, P17, R31, ST1and install T-adapters.

Keep ignition switch to the OFF position for this test.

A.

9.

Readings

If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc. Check the related circuits.

Wiring harness test


Disconnection or
contact with
connector

Air conditioner unit

20-574 1

Resistance

Between M30 (4) and P17 (1)

Max. 1

Between P17 (2) and chassis ground

Max. 1

Between fuse 11 outlet, R31 (2), fuse in unit, R31 (1) and
M30 (6)

Max. 1

9
10

Between ST1 (1) and R31 (3)

Max. 1

Between M29 (2) and ST1 (2)

Max. 1

11

Between M29 (12) and chassis ground

Max. 1

12

Between R31 (4) and M34 (1)

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

TROUBLESHOOTING OF HYDRAULIC AND


MECHANICAL SYSTEM (H MODE)
12
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW . . . . . 20-606
H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . 20-608
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
AUTO-DECELERATOR DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
FINE CONTROL MODE DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
BOOM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
ARM MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
BUCKET MOVES SLOWLY OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
WORK EQUIPMENT HAS BIG TIME LAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT . . . . . . . . . . . . . . . . . 20-614
H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
MACHINE PUSH-UP FUNCTION DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY . . 20-615
H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
MACHINE SWERVES IN TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
MACHINE TRAVELS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-619
H-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED. . . . 20-620
H-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620

PC400LC-7L

20-601 1

TESTING AND ADJUSTING

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

TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS


12

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

PC400LC-7L

20-603 1

TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS


12
This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart (See Section 90
FOLDOUTs for complete hydraulic schematic). Use it as a reference material when troubleshooting the hydraulic and
mechanical systems.

20-604 1

PC400LC-7L

TROUBLESHOOTING

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

12

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE


Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information

Phenomena occurring on machine

Relative information

Information on occurred failures and troubleshooting

Presumed cause and standard value

Cause

Standard value in normalcy and references for troubleshooting

1
2
3

Cause for presumed failure (The <Contents>


attached No. for filing and

The standard values in normalcy by which to judge good or no good about presumed causes.
reference purpose only. It does

References for making judgement of good or no good.


not stand for any priority)

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

Set the working mode at A mode for troubleshooting.

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of
unload valve

Control lever

Unload pressure

All control levers in NEUTRAL

4.121.0 MPa {4210 kgf/cm2}(597142 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


Control lever

Main relief pressure

33.34 - 36.77 MPa {340 - 375kgf/cm2}


Arm, DIGGING
Improper adjustment or
(4836 - 5333 psi)
malfunctioning of main
relief valve
If the pressure does not return to normalcy even after the adjustment, malfunctioning of main relief valve or its internal
failure is suspected. In that case, check the valve itself.

Malfunctioning of self
pressure decompression
valve

Presumed cause andstandard value in normalcy

Stop engine for preparations. Start troubleshooting at engine high idling.


Control lever

Control circuit source pressure

All control levers in NEUTRAL

2.84 - 3.43MPa {29 - 35kgf/cm2}


(412 - 497 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


4

Improper adjustment or
malfunctioning of PC
valve

Oil pressure to be measured

Measurement condition

Oil pressure ratio

Pump delivery pressure

Swing lock: ON
Arm: Digging relief

Approx. 0.6 (Approx. 3/5)

PC valve output pressure

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


5

Malfunctioning of LSEPC valve

Travel speed

Travel control lever

LS-EPC output pressure

Lo

NEUTRAL

Approx. 1.37MPa {Approx. 14 kgf/cm2}


(199 psi)

Hi

OPERATED

0 MPa {0 kgf/cm2}

Stop engine for preparations. Start troubleshooting at engine high idling.


Oil pressure ratio
Oil pressure to be measured
6

Improper adjustment or
malfunctioning of LS
valve

Pump delivery pressure


LS valve output pressure

All control levers in


NEUTRAL
Nearly equal pressure

Travel without load (control lever held at half


stroke)
1
Approx. 0.6 (Approx. 3/5)

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

Piston pump defective

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

The engine speed sharply drops or the engine stalls.

Relative information

Relative Information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Improper adjustment or
malfunctioning of main relief
valve

Control lever

Main relief pressure

Arm, DIGGING

33.34 - 36.77 MPa {340 - 375 kgf/cm2}


(4835 - 5333 psi)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


2

Improper adjustment or
malfunctioning of PC valve

Oil pressure to be measured

Measurement condition

Oil pressure ratio

Pump delivery pressure

Swing lock: ON
Arm: Digging relief

Approx. 0.6 (Approx. 3/5)

PC valve output pressure

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


Oil pressure ratio
Oil pressure to be measured
3

Improper adjustment or
malfunctioning of LS valve

Pump delivery pressure


LS valve output pressure

All control levers in


NEUTRAL

Travel without load (control lever held at half


stroke)

Nearly equal pressure

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

Orifice or filter in servo


equipment clogged

The orifice or filter in the pump servo equipment is suspected of clogging. Check the equipment itself.

Malfunction of servo
piston

The servo piston is suspected of malfunction. Check the piston itself.

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of PPC lock


solenoid valve

Safety lock lever

Solenoid output pressure

Locked

0 MPa {0 kgf/cm2} (0 psi)

Released

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


2

Malfunctioning of self
pressure decompression valve

Control lever

Control circuit source pressure

All control levers in NEUTRAL position

2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)

Piston pump defective

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

---

Presumed cause and standard


value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Hydraulic oil level lowered

Make a visual check.

Quality of hydraulic oil bad

Air may have get mixed with the oil. Make a visual check.

Hydraulic tank cap breather


clogged

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.

Hydraulic tank strainer


clogged

It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
negative pressure in the suction circuit. Make a visual check.

Piston pump defective

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

The auto-decelerator does not work.

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.

Presumed cause and


standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Travel control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Operation

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Malfunctioning of travel PPC


valve (shuttle valve)

H-6
FINE CONTROL MODE DOES NOT FUNCTION
Failure information

The fine control mode poorly functions or its response is slow.

Relative information

Set the working mode at A mode for the troubleshooting.

Cause

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of LS- EPC


valve

Travel speed

Travel control lever

LS-EPC valve output pressure

Lo

NEUTRAL

Approx. 1.37 MPa {Approx. 14 kgf/cm2}


(Approx. 199 psi)

Hi

OPERATED

0 MPa {0 kgf/cm2} (0 psi)

Orifice in LS circuit clogged The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.

Stop engine for preparations. Start troubleshooting at engine high idling.


Oil pressure ratio
Oil pressure to be measured
3

Improper adjustment or
malfunctioning of LS valve

Pump delivery pressure


PC valve output pressure

All control levers in


NEUTRAL

Travel without load (control lever held at half


stroke)

Nearly equal oil pressure

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

Malfunctioning of the servo piston is suspected. Check the piston itself.

20-609 1

TROUBLESHOOTING

H-7

12

H-7
BOOM MOVES SLOWLY OR LACKS POWER
Failure information

The boom moves slowly or lacks power

Relative information

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of right PPC


valve (in boom circuit)

R.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Boom RAISE
Boom LOWER

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Malfunction of merge/ divide


solenoid valve

Travel lever

Solenoid output pressure

Neutral

0 MPa {0 kgf/cm2} (0 psi)

Operated (Note)

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

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.

Malfunction of boom control


valve (check valve)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


13

Boom cylinder defective

Boom cylinder

Amount oil leakage from 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

The arm moves slowly, or lacks power.

Relative information

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of left PPC


valve (arm circuit)

L.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Arm DIGGING
Arm DUMPING

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Presumed cause and standard value in normalcy

Stop engine for preparations. Start troubleshooting at engine high idling.


2

Malfunctioning of merge/
divide solenoid valve

Travel lever

Solenoid output pressure

Neutral

0 MPa {0 kgf/cm2} (0 psi)

Operated (Note)

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Malfunctioning of merge/
divide valve (main and LS
valves)

Malfunctioning of arm control


The spool in the arm control valve (LoHi) is presumed to malfunction. Check the valve itself.
valve (spool)

Malfunctioning of arm control


valve (pressure compensation The pressure compensation valve in the arm control valve (LoHi) is presumed to malfunction. Check the valve
itself.
valve)

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

Malfunction of arm control


valve (quick return valve)

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

Arm cylinder defective

The merge/divide valve of control valve (main and LS valves) is presumed to malfunction. Check the valve itself.

Stop engine for preparations. Start troubleshooting at engine high idling.


Arm cylinder

Amount oil leakage from cylinder

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

The bucket moves slowly, or lacks power.

Relative information

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

Stop engine for preparations. Start troubleshooting at engine high idling.


Malfunctioning of right PPC valve
(bucket circuit)

R.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Bucket DIGGING
Bucket DUMPING

Above 2.75MPa {Above 28 kgf/cm2}


(Above 398 psi)

Malfunctioning of bucket control


valve (spool)

Malfunctioning of bucket control


The pressure compensation valve in the bucket control valve is presumed to malfunction. Check the valve
valve (pressure compensation valve) itself.

Malfunctioning of bucket control


valve (safety and suction valves) or
seal defective

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.

Malfunction of LS shuttle valve


(service valve)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


6

Bucket cylinder defective

Bucket cylinder

Amount oil leakage from 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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard


value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of PPC valve

Malfunctioning of work
equipment control valve
(spool)

20-612 1

Work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Operated

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

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

Work equipment has a bit too fast hydraulic drift


(1) Hydraulic drift of the boom is a bit too fast.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard


value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Boom cylinder defective

Boom control lever (lock valve)


seal defective

The seal at lock valve in the boom control lever is suspected to be defective. Check the valve itself.

Seal at safety valve for lock valve


defective

The seal at the safety valve in the lock valve (Lo) is suspected to be defective. Check the valve itself.

Boom cylinder

Amount oil leakage from cylinder

Raise relief

20 cc/min

Work equipment has a bit too fast hydraulic drift


(2) Hydraulic drift of the arm is a bit too fast.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Arm cylinder defective

Arm cylinder

Amount oil leakage from cylinder

Digging relief

20 cc/min

Arm control valve (safety and


suction valves) seal defective

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.)

Arm control valve (spool) seal


defective

The seal for spool in the arm control valve (LoHi) is suspected to be defective. Check the seal itself.

Arm control valve (pressure


compensation
valve) seal defective

The seal for pressure compensation valve (bottom side) in the arm control valve
(LoHi) is suspected to be defective. Check the seal itself.

Work equipment has a bit too fast hydraulic drift


(3) Hydraulic drift of the bucket is a bit too fast.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Bucket cylinder defective

Bucket cylinder

Amount oil leakage from cylinder

Digging relief

20 cc/min

Bucket control valve (safety and


suction valves) seal defective

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.)

Bucket control valve (spool) seal


defective

The seal for spool in the bucket control valve is suspected to be defective. Check the seal itself.

Bucket control valve


(pressure compensation
valve) seal defective

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


Malfunctioning of LS-EPC
valve

Travel speed

Travel control lever

LS-EPC valve output pressure

Lo

NEUTRAL

Approx. 1.37 MPa {14 kgf/cm2}(199 psi)

Hi

Operation

0 MPa {0 kgf/cm2} (0 psi)

Malfunctioning of control valve


The regeneration valve in the control valve is presumed to malfunction. Check the valve itself.
(regeneration valve) - with
boom and arm only

Malfunctioning of control
valves (safety & suction valve)

Malfunctioning of control valve


(pressure compensation valve) The pressure compensation valve of the control valve is presumed to malfunction. Check the valve itself directly.

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard


value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Control valve (pressure


The seal for pressure compression valve in the control valve is suspected to be defective. Check the seal
1 compensation valve) seal defective itself.

H-14
ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK
One-touch power max. function does not work.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard


value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of 2-stage
solenoid valve

Malfunctioning of main
relief valve

20-614 1

Swing lock switch

Solenoid valve output pressure

OFF

0 MPa {0 kgf/cm2} (0 psi)

ON

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

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

The machine push-up function does not work

Relative information

When carrying out troubleshooting, set the working mode in A-mode.

Presumed cause and standard


value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Prepare with starting switch OFF, then run engine at high idling and carry out troubleshooting.
1

Malfunction of machine push-up


solenoid valve

Malfunction of boom 2 control


valve (safety-suction valve)

Machine push-up switch

Solenoid outlet pressure

OFF

Min. 2.75 MPa {Min. 28 kgf/cm2} (Min. 398 psi)

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

---

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting


The pressure compensation valve for the work equipment with larger load is presumed to malfunction.
Check the valve itself.

Malfunctioning of pressure
compensation valve for work
equipment with larger load

PC400LC-7L

Combination of compound operation

Work equipment with larger load

Work equipment with


smaller load

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.

Presumed cause and standard


value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

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.

Presumed cause and standard


value in normalcy

Failure information

Cause

20-616 1

Malfunctioning of LS shuttle
valve (left travel and swing)

Standard value in normalcy and references for troubleshooting

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

The machine tends to swerve while traveling.

Relative information

Set the working mode at A mode for the troubleshooting.

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of travel PPC


valve

Travel control lever

PPC valve output pressure

Operated to Forward
Operated to Reverse

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Differential output between right and


left sides

0.4 MPa {4 kgf/cm2} (56 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Malfunctioning of self-pressure
decompression valve

Control lever

Control circuit source pressure

All control levers in NEUTRAL

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


Oil Pressure ratio
3

Improper adjustment or
malfunctioning of LS valve

Oil pressure to be measured

All control levers in


NEUTRAL

Travel without load (control lever held at


half stroke)

Pump delivery pressure


LS valve output pressure

1
Nearly equal pressure

Approx. 0.6
(Approx. 3/5)

Stop engine for preparations. Start troubleshooting at engine high idling.


4

Malfunctioning of travel
interlocking solenoid valve

Travel control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Operating one side only

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Malfunctioning of travel
interlocking valve

Malfunctioning of travel control


The spool in the travel interlocking valve is presumed to malfunction. Check the spool itself.
valve (spool)

The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.

Stop engine for preparations. Start troubleshooting at engine high idling.


7

Malfunction of travel motor

Final drive defective

PC400LC-7L

Travel control lever

Amount of oil leakage from travel motor

Travel relief

40 l/min (10.56 gal/min)

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

The machine's travel speed is slow.

Relative information

Set the working mode at A mode for the troubleshooting.

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

1 Malfunctioning of travel PPC


valve

Malfunctioning of
2 self-pressure decompression
valve

Travel control lever

PPC valve output pressure

Operated to Forward
Operated to Reverse

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Output differential between right


and left
or front and rear

Below 0.4 MPa {Below 4 kgf/cm2} (56 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


Control lever

Control circuit source pressure

All control levers in NEUTRAL

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


3 Malfunctioning of LS-EPC
valve

Travel speed

Travel control lever

LS-EPC valve output pressure

Lo

NEUTRAL

Approx. 1.37 MPa {Approx. 14 kgf/cm2}


(0.0199 psi)

Hi

Operated

0 MPa {0 kgf/cm2} (0 psi)

4 Malfunction of travel control


valve (spool)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


7 Malfunction of travel motor

8 Final drive defective

20-618 1

Travel control lever

Amount of oil leakage from travel motor

Travel relief

40 l/min (10.56 gal/min)

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

The machine cannot be easily steered.

Relative information

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of travel PPC valve


(steering spool)

Travel control lever

PPC valve output pressure (steering)

NEUTRAL on both sides

0 MPa {0 kgf/cm2} (0 psi)

Operating one side only

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Malfunctioning of travel interlocking


solenoid valve

Travel control lever

Solenoid valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Operating one side only

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Malfunctioning of travel interlocking


The travel interlocking valve of control valve is presumed to malfunction. Check the valve itself.
valve

Stop engine for preparations. Start troubleshooting at engine high idling.


4

Malfunctioning of merge/ divide


solenoid valve

Travel control lever

Solenoid valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

OPERATED

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Malfunctioning of merge/ divide


valve

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.

Malfunctioning of travel 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)

The suction valve in the travel control valve is presumed to malfunction. Check the valve itself.

Malfunctioning of LS shuttle valve


(bucket)

The LS shuttle valve in the bucket control valve is presumed to malfunction. Check the valve itself.

10

Check valve seal defective at LS oil


pressure pick-up port

The seal in the check valve of LS oil pressure pick-up port is suspected to be defective. Check the seal
itself.

11

Malfunctioning of travel motor


(safety valve)

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

Malfunctioning of travel motor


(check valve)

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

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


Travel speed

Travel control lever

Monitoring [01500]

Lo

690mA
Fine control (to the extent that the
decelerator is released)

Mi

Presumed cause and standard value in normalcy

Malfunctioning of LS-EPC valve

740mA

Hi

0 mA

Stop engine for preparations. Start troubleshooting at engine high idling.


Travel speed

Travel control lever

LS-EPC valve output pressure

Lo

NEUTRAL

Approx.
1.37 MPa {14 kgf/cm2}(0.0199 psi)

Hi

Operation

0 MPa {0 kgf/cm2} (0 psi)

Stop engine for preparations. Start troubleshooting at engine high idling.


2

Malfunctioning of travel
speed solenoid valve

Malfunctioning of travel motor


(speed shifting)

Travel speed

Travel control lever

Solenoid output pressure

Lo

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Hi

Operation

2.84 - 3.43 MPa {29 - 35 kgf/cm2}


(412 - 497 psi)

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Travel control valve (suction valve) seat


defective

The suction valve seat in the travel control valve is suspected of defect. Check the seat itself.

Travel motor (safety valve) seat defective

The safety valve seat in the travel motor is suspected of defect. Check the seat itself.

Travel motor (check valve) seat defective

The check valve seat in the travel motor is suspected of defect. Check the seat itself.

Travel Motor speed

Stop engine for preparations. Start troubleshooting at engine high idling.

Final drive defective

20-620 1

Travel control lever

Amount of oil leakage from travel motor

Travel relief

40 l/min (10.56 gal/min)

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

Machine does not swing


(1) The machine swings neither to the right nor to the left.

Relative information

Set the working mode at A mode for the troubleshooting.


Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.

Presumed cause and standard value in normalcy

Malfunctioning of swing
holding brake solenoid valve

R.H. work equipment control lever

Solenoid valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Swing operated

2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
(holding brake)
Check it directly.

Stop engine for preparations. Start troubleshooting at engine high idling.


3

Improper adjustment or
malfunctioning of swing motor
(safety valve)

Swing lock switch

L.H. work equipment


control lever

Swing relief pressure

ON

Swing relief

27.95 - 32.85 MPa {285 - 335 kgf/cm2}


(4,053 - 4,764 psi)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


4

Swing motor defective

Swing machinery defective

L.H. work equipment control lever

Amount of oil leakage from swing motor

Swing relief

Below 11 l/min (2.9 gal/min)

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.)

Machine does not swing


(2) The machine does not swing in one direction.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of swing PPC


valve

L.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Swing operated

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Malfunctioning of swing control valve (spool)

The spool in the swing control valve is presumed to malfunction. Check the spool itself.

Swing motor (suction valve)


seal defective

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

Swing acceleration is poor, or swing speed is slow


(1) Swing acceleration is poor, or swing speed is slow.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Malfunctioning of LS shuttle valve


The LS shuttle valves for all the control valves are presumed to malfunction. Check them directly.
(all LS shuttles)

Malfunctioning of swing

The swing holding brake portion of the swing motor is presumed to malfunction.

Stop engine for preparations. Start troubleshooting at engine high idling.

Improper adjustment or
malfunctioning of swing motor
(safety valve)

Swing lock switch

L.H. work equipment


control lever

Swing relief pressure

ON

Swing relief

27.95 - 32.85 MPa {285 - 335 kgf/cm2}


(4,053 - 4,764 psi)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


4

Swing motor defective

Swing machinery defective

L.H. work equipment control lever

Amount of oil leakage from swing motor

Swing relief

Below11 l/min (2.9 gal/min)

Inside of the swing machinery is presumed to malfunction. Check itself.


(Whether it is defective or not may well be determined by abnormal noise, abnormal generation of heat and
the mixture of the metal particles in drain oil.)

Failure information

Swing acceleration is poor, or swing speed is slow.


(2) Swing acceleration is poor only on one side, or swing speed is slow.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of swing PPC


valve

L.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Swing operated

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

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 pressure compensation valve in the swing motor is presumed to malfunction.


Check the valve itself.

Swing motor (suction valve)


seal defective

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.

Improper adjustment or
malfunctioning of swing motor
(safety valve)

Swing lock switch

L.H. work equipment


control lever

Swing relief pressure

ON

Swing relief

27.95 - 32.85 MPa {285 - 335 kgf/cm2}


(4,053 - 4,764 psi)

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.

Stop engine for preparations. Start troubleshooting at engine high idling.


2

Swing motor defective

L.H. work equipment control


lever

Amount of oil leakage from swing motor

Swing relief

Below11 l/min (2.9 gal/min)

Failure information

Excessive overrun when stopping swing


(2) Swing acceleration is poor only on one side, or swing speed is slow.

Relative information

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of swing PPC


valve

L.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Swing operated

Above2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

Swing PPC slow return valve


clogged

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.

Swing motor (suction


valve) seal defective

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.)

Swing motor (check


valve) seal defective

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Malfunctioning of swing PPC


valve

L.H. work equipment control lever

PPC valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2}(0 psi)

Swing operated

Above 2.75 MPa {Above 28 kgf/cm2} (Above 398 psi)

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.)

Malfunctioning of swing PPC


slow return valve

Malfunctioning of swing motor


The swing motor shockless valve is presumed to malfunction. Check the valve itself.
(shockless valve)

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

Set the working mode at A mode for the troubleshooting.

Presumed cause and standard value in normalcy

Failure information

Cause

Standard value in normalcy and references for troubleshooting

Malfunctioning of
backpressure valve

The backpressure valve is presumed to malfunction. Check the valve itself.

Malfunction of swing motor


(safety valve)

The safety valve in the swing motor is presumed to malfunction. Check the valve itself.

Malfunction of swing motor


(suction valve)

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.)

Swing machinery defective

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

Presumed cause and standard


value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Stop engine for preparations. Start troubleshooting at engine high idling.


1

Swing and holding brake solenoid


valve malfunctioned

Swing motor (parking brake


portion) malfunctioned

Solenoid valve output pressure

NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Swing operated

2.84 - 3.43 MPa {29 - 35 kgf/cm2}(412 - 497 psi)

The parking portion of the swing motor is suspected of malfunctioning and interior failure. Check that
portion directly.

Swing natural drift is too big.


(2) When the swing holding brake is released.

Failure information

Relative information

Presumed cause and standard value in normalcy

R.H. work equipment control lever

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

Swing control valve (spool)


malfunctioned

The seal in the spool of the swing control valve is suspected of defect. Check the spool itself directly.

Swing control valve (pressure


compensation valve)
malfunctioned

The pressure compensation valve seal in the swing control valve is suspected of defect. Check the valve itself
directly.

Swing motor (safety valve)


defective

The safety valve seal in the swing motor is suspected of defect. Check the valve itself directly.

Swing motor (suction valve)


defective

The suction valve seal in the swing motor is suspected of defect. Check the valve itself directly.

Swing motor (check valve)


defective

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

The return circuit of the attachment circuit does not change.

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.

Presumed cause and standard


value in normalcy

Cause

Standard value in normalcy and references for troubleshooting

Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
1

Malfunction of attachment return


selector solenoid valve

Working mode

Solenoid valve output pressure

Mode E or A

0 MPa {0 kgf/cm2} (0 psi)

Mode B

2.84 - 3.43 MPa {29 - 35 kgf/cm2} (412 - 497 psi)

Malfunction of 2 attachment return


selector valve

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

Flow rate in attachment circuit cannot be adjusted.

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.

Presumed cause and standard


value in normalcy

Cause
1

Malfunction of attachment flow


rate adjustment EPC valve

Standard value in normalcy and references for troubleshooting


The attachment flow rate adjustment EPC valve may have a malfunction. Check it directly.

Keep the engine stopped for the preparations, and keep it running at high idling during the troubleshooting.
2

20-626 1

Malfunction of service PPC valve

Wiring harness connector


Disconnect connector V30 of
attachment flow rate adjustment
EPC valve.

Service pedal

PPC valve output pressure

In NEUTRAL

0 MPa {0 kgf/cm2} (0 psi)

Operated

Above 2.75 MPa {Above 28 kgf/cm2}


(Above 398 psi)

PC400LC-7L

30

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5


REMOVAL AND INSTALLATION OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
STRIPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
ENGINE AND HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
SWING CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
SWING MOTOR AND SWING MACHINERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38

PC400LC-7L

30-1 2

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY


12

MEMORANDUM

30-4 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

12

HOW TO READ THIS MANUAL


REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS

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.

Distinction of new and existing special tools:


N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from already available tools for other models.
Blank: Tools already available for other models, used without any modification.

3.

Circle mark () in sketch column:


A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with
those made by Komatsu in Japan e.g. 79*T--- xxx --- xxxx.

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.

This mark gives guidance or precautions when doing the procedure.


[*1] This mark shows that there are instructions or precautions for installing parts.
This mark shows oil or water to be drained.

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

DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL

This mark gives guidance or precautions when doing the procedure.


This mark stands for a specific coating agent to be used.

This mark indicates the specified torque.

This mark indicates an amount of oil or water to be added.

SKETCHES OF SPECIAL TOOLS

Various special tools are illustrated for the convenience of local manufacture.

30-6 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS DURING OPERATION

12

PRECAUTIONS DURING OPERATION


Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.

PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

If the coolant contains antifreeze, dispose of it correctly.


After disconnecting hoses or tubes, over them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.

1.

Hoses and tubes using sleeve nuts

2.

Nominal
number

Plug (nut end)

02

07376-50210

07221-20210 (Nut), 07222-00210 (Plug)

03

07376-50315

07221-20315 (Nut), 07222-00312 (Plug)

04

07376-50422

07221-20422 (Nut), 07222-00414 (Plug)

05

07376-50522

07221-20522 (Nut), 07222-00515 (Plug)

06

07376-50628

07221-20628 (Nut), 07222-00616 (Plug)

10

07376-51034

07221-21034 (Nut), 07222-01018 (Plug)

12

07376-51234

07221-21234 (Nut), 07222-01219 (Plug)

Sleeve nut (elbow end) Use the two items


below as a set

Split flange type hoses and tubes


Nominal
number

Flange (hose end)

Sleeve head (tube end)

Split flange

04

07379-00400

07378-10400

07371-30400

05

07379-00500

07378-10500

07371-30500

PC400LC-7L

30-7 2

DISASSEMBLY AND ASSEMBLY


3.

PRECAUTIONS DURING OPERATION

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

PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

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

DISASSEMBLY AND ASSEMBLY


12
PRECAUTIONS

PRECAUTIONS DURING OPERATION

WHEN COMPLETING THE OPERATIONS

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

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST


12

Q'ty

Puller

Removal, installation of nozzle holder


assembly

790-331-1110

Wrench

Tightening of cylinder head bolt

795-931-1100

Seal puller

Removal of engine seal

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).

Nature of work, remarks

Press fitting of engine rear seal

O
Press fitting of engine front seal

Removal of fuel supply pump

O
N

Removal, installation of nozzle tip


Removal, installation of engine mount bolt
Stopping of oil

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

Q'ty

Push tool

Removal of shaft

2 790-201-2350

Push tool

Removal of bearing

3 790-201-2510

Press fitting of bearing

Swing motor and swing


machinery assembly

Part No.

Push tool

790-101-5401

Push tool kit

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

Carrier roller assembly

790-101-2510

Block

791-122-1130

Plate

790-101-2550

Leg

Adapter

790-101-2570

Plate

790-101-2560

Nut

790-101-2102

Puller (294 kN {30 t})

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

Cylinder (686 kN {70 t})

790-101-1102

Pump

790-201-1500

Push tool kit

790-201-1660

Plate

790-101-5021

Grip

01010-50816

Bolt

Track roller assembly

Idler assembly

Recoil spring assembly

J
2

PC400LC-7L

Press fitting of bearing inner race


O

Press fitting of bearing

Removal, installation of round nut

Push tool

2 790-101-2740

Press fitting of oil seal

Press fitting of bearing inner race

796T-627-1230

Nature of work, remarks

5 790-201-2870

Final drive assembly

Part Name

Sketch

Necessity

1 796T-627-1630

Symbol

Component

New/remodel

12

Pressing of bearing inner race

Installation of floating seal

Supply of oil

Disassembly, assembly of recoil spring


assembly

1
Installation of dust seal

30-11 2

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

Remover and
installer

Track shoe assembly

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

(For 723-46-45100, 723-46-45500)


796-946-1320

Guide

(For 723-46-40100, 723-46-40601)


796-946-1420
2
Control valve assembly

Guide 21.6

(For 723-46-42800)
796-946-2120

Guide

(For 723-46-44100)
796-946-2220

Guide
Sleeve

(For 723-46-40100, 723-46-40601)


796-946-1430

Sleeve

(For 723-46-42800)
3

796-946-2130

Sleeve

(For 723-46-44100)
796-946-2230

Sleeve

(For 723-46-45100, 723-46-45500)

Center swivel joint


assembly

30-12 2

Replacement of pressure compensation valve seal

(For 723-46-45100, 723-46-45500)


796-946-1330

Pulling out of master pin

(For 723-46-44100)
796-946-2210

Nature of work, remarks

(For 723-46-40100, 723-46-40601)


1

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

Disassembly, assembly of center swivel joint


assembly

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

790-102-4300

Wrench assembly

790-102-4310

Pin

Expander

796-720-1680

Ring (For boom and bucket)

07281-01589

Clamp (For boom and


bucket)

796-720-1690

Ring (For arm)

07281-01919

Clamp (For arm)

790-201-1702

Push tool kit

1 790-502-1003
2

3 790-720-1000

Hydraulic cylinder
assembly

790-201-1851

Push tool (For bucket)

790-201-1861

Push tool (For boom)

790-101-5021

Grip

01010-50816

Bolt

Work equipment
assembly

PC400LC-7L

Part Name

Sketch

Part No.

New/remodel

Q'ty

Cylinder repair stand

Symbol

Component

Necessity

12

Nature of work, remarks

Disassembly, assembly of hydraulic cylinder


assembly
Removal, installation of piston assembly

Installation of piston ring

Press fitting of bushing

790-201-1500

Push tool kit

790-101-5021

Grip

01010-50816

Bolt

790-201-1660

Plate (For bucket)

790-201-1670

Plate (For boom)

790-201-1680

Plate (For arm)

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

Press fitting of dust seal

790-101-4000

Puller (490 kN {50t}, long)

790-101-1102

Pump (294 kN {30t})

Removal of foot pin

30-13 2

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

Operators cab glass

30-14 2

Vacuum pump (100V)

799-703-1110

Vacuum pump (220V)

799-703-1120

Vacuum pump (240V)

799-703-1400

Gas leak tester

793-498-1210

Lifter (Suction cup)

20Y-54-13180

Adapter

Sketch

Service tool kit

799-703-1100

Part Name

New/remodel

799-703-1200

Part No.

Q'ty

Air conditioner assembly

Necessity

Component

Symbol

12

Nature of work, remarks

Collection and supply of air conditioner


refrigerant

Removal and Installation of operators


cab glass

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


12
SKETCHES

SPECIAL TOOL LIST

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

DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

D7. Push tool

E2. Push tool

30-16 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

CONNECTOR REPAIR PROCEDURES

12

CONNECTOR REPAIR PROCEDURES


These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.

CONTACT TERMINAL REMOVAL (HD30 TYPE)


1.

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

DISASSEMBLY AND ASSEMBLY


12
STRIPING

CONNECTOR REPAIR PROCEDURES

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

Wire Gauge Range

Strip Length: mm (in)

0460 - 202 - 20141


0462 - 201 - 20141

20 AWG
20 AWG

3.96 - 5.53 (.156 -.218)


3.96 - 5.53 (.156 -.218)

0460 - 202 - 16141


0462 - 201 - 16141

16, 18 and 20 AWG


16, 18 and 20 AWG

6.35 - 7.92 (.250 -.312)


6.35 - 7.92 (.250 -.312)

0460 - 215 - 16141


0462 - 209 - 16141

14 AWG
14 AWG

6.35 - 7.92 (.250 -.312)


6.35 - 7.92 (.250 -.312)

0460 - 204 - 12141


0462 - 203 - 12141

12 and 14 AWG
12 and 14 AWG

5.64 - 7.21 (.222 -.284)


5.64 - 7.21 (.222 -.284)

0460 - 204 - 08141


0462 - 203 - 08141

8 and 10 AWG
8 and 10 AWG

10.92 - 12.47 (.430 -.492)


10.92 - 12.47 (.430 -.492)

0460 - 204 - 0490


0462 - 203 - 04141

6 AWG
6 AWG

10.92 - 12.47 (.430 -.492)


10.92 - 12.47 (.430 -.492)

Using wire insulation stripers, remove only the measured amount of


insulation from the wire according to the size contact terminal listed in
the Strip Length above.

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

DISASSEMBLY AND ASSEMBLY


12
CRIMPING

CONNECTOR REPAIR PROCEDURES

CONTACT TERMINAL (HD30 TYPE)

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.

Loosen locknut, turn adjusting screw in until it stops.

3.

Insert contact terminal with barrel up. Turn adjusting screw


counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4.

Insert wire into contact terminal. Be sure contact terminal is


centered between indicators.

5.

Close crimp tool handle until crimp cycle is completed.

6.

Release the tool handle and remove the crimped contact terminal.

7.

Using the inspection hole in the contact terminal inspect the


crimped contact terminal to ensure that all strands are in the
crimped barrel.

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

DISASSEMBLY AND ASSEMBLY


12
INSERTION

OF CONTACT TERMINAL (HD30 TYPE)

1.

Grasp contact terminal approximately 25.2mm (1in) behind the


crimped barrel.

2.

Holding connector with rear grommet facing you.

3.

Insert completed contact terminal straight into connector grommet


until a positive stop is felt.

4.

Once contact terminal is in connector, a slight tug will confirm that


the contact terminal is properly locked in place.

5.

For unused wire cavities, insert sealing plugs for full environmental
sealing.

30-20 2

CONNECTOR REPAIR PROCEDURES

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


12
CONTACT

TERMINAL REMOVAL (DT TYPE)

1.

Remove the wedge lock using needle nose pliers or a hooked


shaped
wire.

2.

Pull the wedge lock straight out and save for reinstallation.

3.

To remove the contact terminal gently pull the wire backwards


while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.

4.

Hold the rear seal grommet in place and pull the contact terminal
out of the connector.

PC400LC-7L

CONNECTOR REPAIR PROCEDURES

30-21 2

DISASSEMBLY AND ASSEMBLY


12
STRIPING

CONNECTOR REPAIR PROCEDURES

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

Wire Gauge Range

Strip Length: mm (in)

0460 - 202 - 20141


0462 - 201 - 20141

20 AWG
20 AWG

3.96 - 5.53 (.156 -.218)


3.96 - 5.53 (.156 -.218)

0460 - 202 - 16141


0462 - 201 - 16141

16, 18 and 20 AWG


16, 18 and 20 AWG

6.35 - 7.92 (.250 -.312)


6.35 - 7.92 (.250 -.312)

0460 - 215 - 16141


0462 - 209 - 16141

14 AWG
14 AWG

6.35 - 7.92 (.250 -.312)


6.35 - 7.92 (.250 -.312)

0460 - 204 - 12141


0462 - 203 - 12141

12 and 14 AWG
12 and 14 AWG

5.64 - 7.21 (.222 -.284)


5.64 - 7.21 (.222 -.284)

0460 - 204 - 08141


0462 - 203 - 08141

8 and 10 AWG
8 and 10 AWG

10.92 - 12.47 (.430 -.492)


10.92 - 12.47 (.430 -.492)

0460 - 204 - 0490


0462 - 203 - 04141

6 AWG
6 AWG

10.92 - 12.47 (.430 -.492)


10.92 - 12.47 (.430 -.492)

Using wire insulation stripers, remove only the measured amount of


insulation from the wire according to the size contact terminal listed in
the Strip Length above.

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

DISASSEMBLY AND ASSEMBLY


12
CRIMPING

CONNECTOR REPAIR PROCEDURES

CONTACT TERMINAL (DT TYPE)

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.

Loosen locknut, turn adjusting screw in until it stops.

3.

Insert contact terminal with barrel up. Turn adjusting screw


counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4.

Insert wire into contact terminal. Be sure contact terminal is


centered between indicators.

5.

Close crimp tool handle until crimp cycle is completed.

6.

Release the tool handle and remove the crimped contact terminal.

7.

Using the inspection hole in the contact terminal inspect the


crimped contact terminal to ensure that all strands are in the
crimped barrel.

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

DISASSEMBLY AND ASSEMBLY


12
INSERTION

CONNECTOR REPAIR PROCEDURES

OF CONTACT TERMINAL (DT TYPE)

1.

Grasp the crimped contact terminal approximately 25.2mm (1in)


behind the crimped barrel.

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

RADIATOR

12

RADIATOR
REMOVAL
1.

Remove cover (1).

2.

Drain the coolant.


Coolant: Approximately 35 L (9.25 gal)

3.

Erect the engine hood according to the following procedure.


A. Open engine hood (2) and sling it temporarily.
When slinging the engine hood, take care not to damage the
rubber seal.
B. Prepare M10 bolt [1].
When removing the radiator, L = 50 or longer.
When removing the oil cooler, L = 70 or longer.
C. Remove bolt (4).
D. Remove pin (5) from the lower part of stay (3).
E. Adjust the engine hood so that center hole A of stay (3) will be at
the bolt (4).
F.

Install stay (3) with bolt [1] and fix engine hood (2) vertically.

4.

Disconnect reservoir tank hose (6).


Disconnect the hose from the radiator.

5.

Disconnect radiator hoses (7), (8), and (9). [*1]

6.

Remove covers (10) and (11).

30-26 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

RADIATOR

12
7. Remove cover (12).
8.

Disconnect radiator hose (13). [*1]

9.

Remove 2 mount bolts (14).

10. Lift off radiator assembly (15).


Radiator assembly: 30 kg (66.13 lb)

PC400LC-7L

30-27 2

DISASSEMBLY AND ASSEMBLY

RADIATOR

12
INSTALLATION

Carry out installation in the reverse order to removal.


Refilling with coolant
Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.
Coolant: Approximately 35 L (9.25 gal)

[*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

DISASSEMBLY AND ASSEMBLY

HYDRAULIC OIL COOLER

12

HYDRAULIC OIL COOLER


REMOVAL
1.

Remove cover (1).

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.

Erect the engine hood according to the following procedure.


A. Open engine hood (100) and sling it temporarily.
When slinging the engine hood, take care not to damage the
rubber seal.
B. Prepare M10 bolt [1].
C. Remove bolt (102).
D. Remove pin (103) from the lower part of stay (101).
E. Adjust the engine hood so that center hole A of stay (101) will be
at the bolt (102).
F.

4.

Install stay (101) with bolt [1] and fix engine hood (100) vertically.

Remove covers (3) and (4).

PC400LC-7L

30-29 2

DISASSEMBLY AND ASSEMBLY

HYDRAULIC OIL COOLER

12
5. Remove hydraulic oil cooler tube mount bolts (5) and (6).
6.

Remove right and left hydraulic oil cooler mount bolts (7).

7.

Remove 3 hydraulic oil cooler-side mount bolts (8).


When removing 1 of the 3 bolts which is hidden behind cover B,
pull cover B lightly.
Bolt [1] is used to fix the engine hood vertically.

8.

Remove the net on the outside of the hydraulic oil cooler.

9.

Lift off hydraulic oil cooler assembly (9).


Hydraulic oil cooler: 50 kg (110 lb)

INSTALLATION

Carry out installation in the reverse order to removal.


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.

30-30 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

12

ENGINE AND HYDRAULIC PUMP

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.

Remove the 4 engine undercovers.

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.

Drain the coolant.


Coolant: Approximately 35 L (9.25 gal)

4.

Close the fuel stop valve of the fuel tank.

5.

Erect the engine hood according to the following procedure.


A. Open engine hood (100) and sling it temporarily.
When slinging the engine hood, take care not to damage the
rubber seal.
B. Prepare M10 bolt [1].
C. Remove bolt (102).
D. Remove pin (103) from the lower part of stay (101).

PC400LC-7L

30-31 2

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

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.

Remove tube (1). [*1]


Remove the tube and bracket together.

7.

Disconnect clamp (2) and pipe (3). [*2]


Remove the clamp, pipe, and bracket (4) together.

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]

10. Remove covers (12) and (13).


11. Remove fan guard (14).
Bolt [1] is used to fix the engine hood vertically.

30-32 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

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]

16. Remove cover (23).


17. Disconnect radiator hose (24). [*4]

18. Disconnect heater hose (25).

PC400LC-7L

30-33 2

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

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).

21. Open the main pump side cover.


22. Lift off covers (30) and (31) together.
23. Remove cover (32) and stay (33).

24. Disconnect the following 2 pump wiring connectors.


(34): V22 (PC-EPC solenoid valve) Band color: Red
(35): V21 (LS-EPC solenoid valve) Band color: White
25. Disconnect the following 10 hoses and 1 tube.
(36): EPC basic pressure port hose (Band color: Yellow)
(37): Rear pressure port hose (Band color: Yellow)
(38): Rear pump discharge port hose
(39): Front pump discharge port hose

30-34 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


12

ENGINE AND HYDRAULIC PUMP

(40): Drain port hose


(41): Front load pressure input port hose
(42): Rear load pressure input port hose (Band color: Red)
(43): Front pressure input port hose
(44): Pump suction port tube

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]

28. Lift off engine and hydraulic pump assembly (48).


Check that all the wires and pipes have been disconnected.
Engine and hydraulic pump assembly:
1,700 kg (3,748 lb)

PC400LC-7L

30-35 2

DISASSEMBLY AND ASSEMBLY

ENGINE AND HYDRAULIC PUMP

12
INSTALLATION

Carry out installation in the reverse order to removal.

[*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)

Refilling with coolant


Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system.
Then, check the coolant level again.
Coolant: Approximately 35 L (9.24 gal)

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.
Hydraulic oil: Approximately 335 L (88.4 gal)

Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.

30-36 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SWING CIRCLE

12

SWING CIRCLE
REMOVAL
1.

Remove the revolving frame assembly. For details, see REMOVAL


OF REVOLVING FRAME ASSEMBLY.

2.

Sling swing circle assembly (1) by 3 points temporarily, remove 40


mount bolts, and lift off the swing circle assembly. [*1]
Swing circle assembly: 600 kg (1,323 lb)

INSTALLATION

Carry out installation in the reverse order to removal.

[*1]
Mating face of swing circle: Gasket sealant (LG-6)

Threads of swing circle mount bolt: Adhesive (LT-2)

Swing circle mount bolt: 824 - 1,030 Nm {84 - 105 kgm}


(608 - 759 lbf ft)
Target: 927 Nm {94.5 kgm} (683.7 lbf ft)
When installing the swing circle to the track frame, bring soft zone mark S of the inner race and soft zone mark P of the
outer race to the right side of the chassis as shown below.
Quantity of grease in grease bath: Grease (G2-LI), 33 L (8.7 gal)
(Use GLT2-LI for 50C (138.2F) specification)

PC400LC-7L

30-37 2

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

12

SWING MOTOR AND SWING MACHINERY


REMOVAL
WARNING! Release the residual pressure in the hydraulic circuit. Refer to the Releasing of Residual
Pressure in Hydraulic Circuit section in the TESTING AND ADJUSTING chapter of this
manual.
WARNING! Lower the work equipment to the ground for oil filler cap on the fuel tank to release the
residual pressure inside the tank and move the safety lock lever to the LOCK position.
1.

Disconnect five swing motor hoses (1) through (5).


(1): Between swing motor and control valve (MA port)
(2): Between swing motor and control valve (MB port)
(3): Suction hose (S port)
(4): Drain hose (T port)
(5): Swing brake releasing pilot hose (B port)

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

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

12
INSTALLATION

Install in reverse order of removal.

[*1]
Mount bolt: 824 - 1,030 Nm {84 - 105 kgm} (608 - 759 lbf ft)

Refilling hydraulic oil


Refill hydraulic oil through the oil filler port to the specified level. Let the oil circulate in the hydraulic system by starting
the engine. Then check the oil level again.
Air bleeding
Refer to the Air Bleeding of Various Parts section in the TESTING AND ADJUSTING chapter of this manual.

PC400LC-7L

30-39 2

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

Push tool

790-201-2350

Push tool

790-201-2510

Push tool

790-101-5401

Push tool kit

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.

Swing motor assembly


A. Set the swing motor and swing machinery assembly on block [1].
B. Remove 10 mount bolts and lift off swing motor assembly (1).
Swing motor assembly: 115 kg (254 lb)

3.

No. 1 sun gear


Remove No. 1 sun gear (2).

30-40 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

12
4. No. 1 carrier assembly
A. Remove No. 1 carrier assembly (3).

B. Disassemble the No. 1 carrier assembly according to the


following procedure. Remove snap ring (4), and then remove
shaft (5), gear (6), bearing (7), thrust washer (8), and plate (9).

5.

Ring gear
Remove the mount bolts and ring gear (10).

6.

No. 2 sun gear


Remove No. 2 sun gear (11).

PC400LC-7L

30-41 2

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

12
7. Bolt
Remove holder mount bolt (12).

8.

No. 2 carrier assembly


A. Lift of No. 2 carrier assembly (13).

B. Disassemble the No. 2 carrier assembly according to the


following procedure.
i. Push in pin (14) and drive out shaft (15) from carrier (16).
After removing the shaft, remove pin (14).
ii.

Remove thrust washer (17), gear (18), bearing (19), and


thrust washer (20).

iii. Remove plate (21).

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

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

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

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

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)

Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (73 - 90 lbf ft)


Oil seal lip: Grease (G2-LI)

30-44 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


3.

SWING MOTOR AND SWING MACHINERY

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.

No. 2 carrier assembly


A. Assemble the No. 2 carrier assembly according to the following
procedure.
There is a caulking mark made when the pin was inserted at
the end of carrier side hole a and the inside wall of the hole
is swelled at that mark. Flatten the swelled part in advance.
i.

Install plate (21) to carrier (16).

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

DISASSEMBLY AND ASSEMBLY


12

SWING MOTOR AND SWING MACHINERY

When inserting the pin, do not set the 3 claws (parts a) on


the periphery to the thin part of the carrier (part b). The thin
part may be on the opposite side, however. Check each carrier
and avoid setting a claw to the thin part.
After inserting the pin, caulk the pin part of the carrier.
B. Install No. 2 carrier assembly (13).

5.

Bolt and O-ring


A. Tighten bolt (12).
Threads of mount bolt: Adhesive (LT-2)

Mount bolt:
343 - 427 Nm {34 - 43.5 kgm} (253 - 314 lbf ft)
B. Fit the O-ring to case (31).

6.

No. 2 sun gear


Install No. 2 sun gear (11).

7.

Ring gear
Using the eyebolt (M12 x 1.75), install ring gear (10).

30-46 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

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.

Degrease the mating faces of ring gear (10) and case.


Never stick gasket sealant to the mating faces of ring gear (10)
and case.
Mount bolt:
245 - 309 Nm {25 - 31.5 kgm} (181 - 227 lbf ft)
Add engine oil (EO30-CD) at this time.

8.

No. 1 carrier assembly


A. Assemble the No. 1 carrier assembly according to the following
procedure.
i.

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

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

12
B. Install No. 1 carrier assembly (3).

9.

No. 1 sun gear assembly


Install No. 1 sun gear (2).

Take care not to install the No. 1 sun gear upside down.
Install the No. 1 sun gear with the tooth (part e) down.

10. Swing motor assembly


Install swing motor assembly (1) to ring gear (10).
When installing the swing motor assembly, set the relief valve
(part f) and the projection of the case (part c) as shown in the
following figure.
Degrease the mating faces of swing motor assembly (1) and ring
gear (10).
Mating faces of swing motor assembly (1) and ring gear
(10): Gasket sealant (LG-6)
Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (73 - 90 lbf ft)
Swing motor assembly: 115 kg (254 lb)

30-48 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

SWING MOTOR AND SWING MACHINERY

Refilling with oil


Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W-30K for extremely cold district) through the oil filler to
the specified level.
Swing machinery case: Approximately 21 L (5.5 gal)

PC400LC-7L

30-49 2

DISASSEMBLY AND ASSEMBLY

SPROCKET

12

SPROCKET
REMOVAL
1.

Remove track shoe assembly. For details, see REMOVAL OF TRACK


SHOE ASSEMBLY.

2.

Swing work equipment 90, push up chassis with work equipment and
place block [1] between track frame and track shoe.

3.

Remove mount bolts and lift off sprocket (1). [*1]


Sprocket: 70 kg (154.3 lb)

INSTALLATION

Install in reverse order of removal.

[*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

DISASSEMBLY AND ASSEMBLY

TRAVEL MOTOR AND FINAL DRIVE

12

TRAVEL MOTOR AND FINAL DRIVE


REMOVAL
1.

Remove the sprocket. For details, see Removal of sprocket.


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.

2.

Remove cover (1).

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

Carry out installation in the reverse order to removal.

[*1]
Mount bolt: 490 - 608 Nm {50 - 62 kgm} (362 - 448 lbf ft)

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
See TESTING AND ADJUSTING, Bleeding air from each part.

PC400LC-7L

30-51 2

DISASSEMBLY AND ASSEMBLY

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

Puller (30 tons)

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

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

12
3. Spacer
Remove spacer (2).

4.

No. 1 carrier assembly


A. Remove No. 1 carrier assembly (3).

B. Disassemble the No. 1 carrier assembly according to the


following procedure.

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).

No. 1 sun gear shaft


Remove spacer (4), No. 1 sun gear (12), and No. 2 sun gear (13).

PC400LC-7L

30-53 2

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

12
6. Thrust washer
Remove thrust washer (14).

7.

No. 2 carrier assembly


A. Sling No. 2 carrier assembly (15) with wires, etc. and remove it.

B. Disassemble No. 2 carrier assembly according to the following


procedure.

8.

i.

Push in pin (16) to drive out shaft (17) from carrier (18).
After removing the shaft, remove pin (16).

ii.

Remove thrust washer (19), gear (20), bearing (21), and


thrust washer (22).

Nut
A. Remove lock plate (23).

30-54 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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.

B. Disassemble hub assembly (25) according to the following


procedure.
i.

Remove bearing (26) from hub (32).

ii.

Remove floating seal (27) from hub (32).

PC400LC-7L

30-55 2

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE

12
iii. Remove bearings (28) and (29) from hub (32).

C. Remove floating seal (30) from travel motor (31).

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

DISASSEMBLY AND ASSEMBLY

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).

B. Using tool E3, install floating seal (27) to hub (32).


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.

C. Install collar (33) and bearing (34) to travel motor (31).

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

DISASSEMBLY AND ASSEMBLY

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.

Under the condition in E above, measure dimension a.

G. Measure thickness b of nut (24).


H. Obtain a - b = c.
I.

Using tool D1, tighten nut (24) until dimension c is as follows.


Dimension c: c +0.07
-0.03 mm

30-58 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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.

K. Install lock plate (23), fitting it to the motor spline.


Threads of mount bolt: Adhesive (LT-2)

Mount bolt:
66.2 7.4 Nm {6.75 0.75 kgm} (48.8 5.4 lbf ft)

3.

No. 2 carrier assembly


A. Assemble the No. 2 carrier assembly according to the following
procedure.
There is a caulking mark made when the pin was inserted at
the end of carrier side hole h and the inside wall of the hole
is swelled at that mark. Flatten the swelled part in advance.
i.

Install bearing (21) to gear (20) and fit top and bottom thrust
washers (19) and (22), and then set the gear assembly to
carrier (18).

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.

iii. Insert pin (16).


After inserting the pin, caulk the pin part of the carrier.
After assembling the carrier assembly, check that the gear
(20) turns smoothly.

PC400LC-7L

30-59 2

DISASSEMBLY AND ASSEMBLY

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.

No. 2 sun gear


Install spacer (4) and No. 2 sun gear (13).

6.

No. 1 carrier assembly


A. Assemble the No. 1 carrier assembly according to the following
procedure.
There is a caulking mark made when the pin was inserted at
the end of carrier side hole h and the inside wall of the hole
is swelled at that mark. Flatten the swelled part in advance.
i.

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

DISASSEMBLY AND ASSEMBLY

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.

iii. Insert pin (5).


After inserting the pin, caulk the pin part of the carrier.
After assembling the carrier assembly, check that the gear (9)
turns smoothly.

B. Install No. 1 carrier assembly (4).

7.

No. 1 sun gear shaft


Install No. 1 sun gear shaft (12).

8.

Spacer
Install spacer (2).

9.

Cover
Using eyebolts [2], install cover (1) and tighten the mount bolts.
Cover mount face: Gasket sealant (LG-6)

Mount bolt: 98 - 123 Nm {10 - 12.5 kgm} (72 - 90 lbf ft)

Refilling with oil


Tighten the drain plug and add engine oil (EO30-CD, or SHC 5W30K for extremely cold district) through the oil filler.
Final drive case: Approximately 11 L (2.9 gal)
After installing the final drive assembly to the chassis, check the oil level again at the specified position.

PC400LC-7L

30-61 2

DISASSEMBLY AND ASSEMBLY

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

Carrier roller assembly: 35 kg (78 lb)

ASSEMBLY

Press fitting of support (2)


A. The threads of shaft (1) must be in the range of the following figure.
B. Press fitting dimension of shaft: (Shown in the following figure)
C. Using push tool [1], press fit support (2) to shaft (1).
At this time, apply press fitting force of at least 79 kN {8.1 tons}.

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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

Track roller assembly: 80 kg (176 lb)

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.

Track roller: 280 - 310 cc (EO30-CD)

Plug: 10 - 20 Nm {1 - 2 kgm} (7.37 - 14.7 lbf ft)

30-64 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

IDLER

12
6. Remove bushing (12) from idler (5).

ASSEMBLY
1.

Press fit bushings (12) (on both sides) to idler (5).

2.

Fit the O-ring and install support (10) to shaft (11) with bolt (9) and
tighten nut (8).

Install the shaft with the UP mark up.

3.

Using tool H, install floating seal (7) to idler (5) and shaft and support
assembly (6).

30-66 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

IDLER

12 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 H 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 9 - 11 mm.

4.

Install shaft and support assembly (6) to idler (5).

5.

Similarly, using too H, install floating seal (4) to idler (5) and support
(3).

PC400LC-7L

30-67 2

DISASSEMBLY AND ASSEMBLY

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.

Add oil and tighten the plug.


Quantity of oil: Approximately 345 10 cc (EO-30CD)

Plug: 130 - 180 Nm {13 - 18 kgm} (96 - 132 lbf ft)

30-68 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

Push tool kit

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

Recoil spring (Excluding idler): 900 kg (1985 lb)

DISASSEMBLY
1.

Remove piston assembly (2) from recoil spring assembly (1).

2.

Disassembly of recoil spring assembly


A. Set tool J1 to recoil spring assembly (1).
WARNING! Since the installed load of the spring is
large and dangerous, set the tool
securely.

Installed load of spring: 239.037 kN {24,375 kg} (53,738 lbf)


B. Apply oil pressure gradually to compress the spring and remove
lock plate (3) and nut (4).
Compress the spring to a degree that you can loosen the nut.
Release the oil pressure gradually to reduce the spring tension
to 0 (zero).
Free length of spring: 845.3 mm (33.2 in)
C. Remove yoke (6), cylinder (7), collar (8), and dust seal (9) from
spring (5).
3.

Disassembly of piston assembly


A. Remove lock plate (11) from piston (10), and then remove valve (12).
B. Remove snap ring (13), U-packing (14), and ring (15).

PC400LC-7L

30-69 2

DISASSEMBLY AND ASSEMBLY

RECOIL SPRING

12
ASSEMBLY
1.

Assembly of piston assembly


A. Install ring (15) and U-packing (14) to piston (10) and secure
them with snap ring (13).
B. Tighten valve (12) temporarily and secure it with lock plate (11).

2.

Assembly of recoil spring assembly


A. Using tool J2, install dust seal (9) to cylinder (7).

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)

C. Apply oil pressure gradually to compress the spring and tighten


nut (4) so that installed length of the spring will be a, and then
secure it with lock plate (3).
Installed length of spring a: Approximately 690 mm
D. Remove recoil spring assembly (1) from tool J1.
3.

Install piston assembly (2) to recoil spring assembly (1).


Sliding parts of piston: Grease (G2-LI)

Wear ring: 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

DISASSEMBLY AND ASSEMBLY

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.

Using tool K, remove master pin (1). [*3]

5.

Move the master pin forward and set block [1] under the track shoe in
front of the idler.

6.

Pull out pusher K.

7.

Move the machine in reverse slowly to expand the track shoe. [*4]

PC400LC-7L

30-71 2

DISASSEMBLY AND ASSEMBLY

TRACK SHOE

12
INSTALLATION

Carry out installation in the reverse order to expansion.

[*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

Apply grease to the contact faces of dust seal (5) and


bushing (4) (all over the end face of the dust seal or
bushing) (parts marked Q). Do not apply grease to the
pars marked X, however.
R: Detail of regular pin position
M: Detail of master pin position
(Pins are not inserted, however)
[*4]
Set the track shoe and sprocket (4) as shown in the following figure
(on both right and left sides).

30-72 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

12

AIR CONDITIONER UNIT

Service tool kit

799-703-1100

Vacuum pump (100V)

799-703-1110

Vacuum pump (220V)

799-703-1120

Vacuum pump (240V)

799-703-1400

Gas leak tester

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.

Swing the upper structure by 90.

2.

Open the engine hood.

3.

Connect tool Q to cap [1] and collect the air conditioner refrigerant.

4.

Remove rear covers (1), (2), (3), and (4).

5.

Remove duct (5), cover (6), and plate (7).

6.

Remove plate (8) and duct (9).


Remove the duct lock clip.

7.

Remove ducts (10) and (11).

PC400LC-7L

30-73 2

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

12
8. Disconnect connectors D01 (12), D02 (13), C09 (14), R22 (15), R20
(16), and K19 (17).
9.

Remove and sling controller (18).

10. Remove plate (19).


11. Disconnect air conditioner unit connectors M27 (20) and M33 (21).

12. Remove the air conditioner unit undercover.


Part A

13. Remove mount bolt (24) and connector (25). [*1]


14. Disconnect heater hoses (22) and (23) and air conditioner tube (26).
[*1]
Put tags to the disconnected hoses and tubes to prevent a mistake
in re-connecting them.

15. Remove the 7 mount bolts and air conditioner unit assembly (27).

30-74 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

AIR CONDITIONER UNIT

12
INSTALLATION

Carry out installation in the reverse order to removal.


When installing the air conditioner circuit hoses, take care that dirt, water, etc. will not enter them.
When connecting each air conditioner hose, check that the O-ring is fitted to the joint.
Check that each O-ring is free from flaw and deterioration.

[*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)

Charging air conditioner with refrigerant gas


Using tool Q, charge the air conditioner circuit with refrigerant (HFC R134a) from the compressor.
Quantity of refrigerant: 950 50 g

PC400LC-7L

30-75 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB

12

OPERATORS CAB
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.

Remove rear covers (1), (2), (3), and (4).

2.

Remove duct (5), cover (6), and plate (7).

3.

3. Remove plate (8), duct (9) and the element.


Remove the duct lock clip.

4.

Remove clip (10) and disconnect cab wiring connectors M45 (11),
H08 (12), and H09 (13).

5.

Remove air conditioner connector plate (14).

6.

Disconnect connectors M71 (15), H10 (16), H11 (17), and H12 (18).

7.

Disconnect upper and lower duct joints (19) and (20).

8.

Remove controller sub-plate (21) and incline it against the air conditioner.

30-76 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB

12
9. Remove cover (22) and floor mat (23).

10. Move right console (24) into the cab.


11. Remove monitor panel undercover (25).

12. Disconnect cab wiring connector W04 (26) (Wiper motor).


13. Remove ducts (27) and (28).
Both (27) and (28) are two in number.
Cut the tie-wrap on the monitor wiring harness.
14. Remove cover (29) and monitor assembly (30).

15. Disconnect radio antenna (31).


16. Remove clip (32) and take wiring harness (33) out of grommet (34).

PC400LC-7L

30-77 2

DISASSEMBLY AND ASSEMBLY

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

B. Bracket (42) for monitor panel assembly (30)


Part No.: 208-53-13910

INSTALLATION

Carry out installation in the reverse order to removal.

30-78 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

MONITOR

12

MONITOR
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.

Remove cover (1) and disconnect wiring connector P15 of air


conditioner sunlight sensor (2).
Raise and remove the cover.

2.

Remove the 3 mount screws and monitor assembly (3).


Disconnect monitor panel wiring connectors P01, P02, and P70
before removing the monitor assembly.

INSTALLATION

Carry out installation in the reverse order to removal.

PC400LC-7L

30-79 2

DISASSEMBLY AND ASSEMBLY

PUMP CONTROLLER

12

PUMP CONTROLLER
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.

Remove covers (1), (2), and (3).

2.

Disconnect pump controller wiring connectors C01 (4), C02 (5), and
C03 (6).

3.

Remove the 4 mount bolts and pump controller assembly (7).

INSTALLATION

Carry out installation in the reverse order to removal.

30-80 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

ENGINE CONTROLLER

12

ENGINE CONTROLLER
REMOVAL
WARNING! Disconnect the cable from the negative
() terminal of the battery.
1.

Open the right side cover (cooler).

2.

Remove bracket (1).

3.

Remove the 4 mount bolts and engine controller assembly (2).

4.

Disconnect engine controller wiring connectors CB1 (3), CB2 (4), and
CB3 (5).

INSTALLATION

Carry out installation in the reverse order to removal.

PC400LC-7L

30-81 2

DISASSEMBLY AND ASSEMBLY

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.

Remove the work equipment assembly. For details, see WORK


EQUIPMENT.

2.

Remove the counterweight assembly. For details, see


COUNTERWEIGHT.

3.

Disconnect 4 boom cylinder hoses (1).


Plug the hoses to stop oil.

4.

Sling boom cylinder assembly (2) temporarily.

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

DISASSEMBLY AND ASSEMBLY

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.

Using a lever block, sling the revolving frame assembly temporarily,


balancing it in each direction.
Put wood liners to the rear side of the frame.
Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
If the engine hood interferes with the sling, erect the engine
hood, referring to RADIATOR.

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

DISASSEMBLY AND ASSEMBLY

REVOLVING FRAME

12
INSTALLATION

Carry out installation in the reverse order to removal.

[*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)

Threads of revolving frame mount bolt: Adhesive (LT-2)

Revolving frame mount bolt


1. Tighten the bolts marked with A (at 4 places) according to the following steps 1) 3).
1) Tighten each bolt to 392 Nm {40 kgm} (289 lbf ft) first.
2) Then, tighten the bolt by 90 5.
Make a mark on the bolt head with a marker pen (to check the angle).
3) The tightening torque of the bolt tighten in 2) above must be 1,176 Nm {120 kgm} (867 lbf ft)
or larger.
2. Tighten each bolt 208-25-71230 which is not marked with A according to above steps 1) 3).
If the tightening torque reaches 2,254 Nm {230 kgm} (1662 lbf ft) before completing the above
steps and the tightening angle is 35 95, however, stop tightening.

Marks P and S are the soft zone points.


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 air from the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air from each part.

30-84 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

COUNTERWEIGHT

12

COUNTERWEIGHT
REMOVAL
1.

Set eyebolt [1] to counterweight assembly (1).

2.

Remove 4 mount bolts (2). [*1]


Check where shims have been used.

3.

Lift off counterweight assembly (1). [*2]


When lifting off the counterweight, take care not to strike it
against the engine, radiator and cooler assembly, etc.
Counterweight assembly: 9,500 kg (20,944 lb)

INSTALLATION

Carry out installation in the reverse order to removal.


If heat insulation cover (3) of the engine compartment is flattened,
replace it.

[*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

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

12

HYDRAULIC TANK
REMOVAL
1.

Remove 3 lower covers (1).

2.

Drain the oil from the hydraulic tank.


Capacity of hydraulic tank:
Approximately 335 L (88.5 gal)

3.

Open engine hood (2) and remove control valve top cover (3).

4.

Remove cover (4).

5.

Disconnect drain hoses (5) and (6).

6.

Disconnect block (7).

7.

Disconnect drain hoses (8), (9), and (10).

8.

Disconnect 2 clamps (11).

9.

Remove side cover (12).

30-86 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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).

13. Lift off hydraulic tank assembly (16).


Hydraulic tank assembly: 200 kg (441 lb)

INSTALLATION

Carry out installation in the reverse order to removal.


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.
Capacity of hydraulic tank: Approximately 335 L (88.5 gal)
Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)

Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.

PC400LC-7L

30-87 2

DISASSEMBLY AND ASSEMBLY

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.

Remove 2 lower covers (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.

Drain the oil from the flywheel housing.

4.

Open the main pump side cover.

5.

Open the engine hood.

6.

Lift off covers (2) and (3) together.

7.

Remove cover (4).

8.

Remove stay (5).

30-88 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

11. Sling hydraulic pump assembly (18) temporarily and remove 12


mount bolts (17).

12. Lift off hydraulic pump assembly (18). [*1]


Hydraulic pump assembly: 255 kg (563 lb)

PC400LC-7L

30-89 2

DISASSEMBLY AND ASSEMBLY

HYDRAULIC PUMP

12
INSTALLATION

Carry out installation in the reverse order to removal.

[*1]
Hydraulic pump involute spline: Anti-friction compound (LM-G)

Mating face of hydraulic pump case: Gasket sealant (LG-6)

Refilling with oil


Flywheel housing drain plug: 42.1 - 70.6 Nm {4.3 - 7.2 kgm} (31 - 52 lbf ft)
Add oil through the oil filler to the specified level.

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.
Capacity of hydraulic tank: Approximately 335 L (88.5 gal)
Quantity of oil in tank (Center of oil level gauge): 248 L (65.5 gal)

Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.

30-90 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT

12

OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT


REMOVAL
1.

Remove the hydraulic pump assembly. Refer to the HYDRAULIC


PUMP section.

2.

Remove snap ring (1) and then remove spacer (2).

3.

Pry off oil seal (3) with a screwdriver. [*1]


When attempting to pry off the seal, do not damage the shaft.

INSTALLATION

Install in reverse order of removal.

[*1]
Oil seal lip portion: Grease (G2-LI)

Oil seal outer circumference: Grease (G2-LI)

Coat the oil seal outer circumference thinly with grease.


Press-fit oil seal (3), using tool.

PC400LC-7L

30-91 2

DISASSEMBLY AND ASSEMBLY

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.

Open engine hood (1).

2.

Remove control valve top cover (2).

3.

Remove partition covers (3), (4), and (5) between the engine and
control valve.

4.

Remove the control valve bottom cover.

5.

Disconnect the 2 wiring connectors and 8 hoses.


(6): A51 (Front pump pressure sensor)
(7): A52 (Rear pump pressure sensor)
(8): Port PS hose (Hose band: Yellow-Blue)
(9): Port PST hose (Hose band: Brown)
(10): Port PPS2 hose (Rear pump, red)
(11): Port PR hose (Solenoid)
(12): Port PR hose (Pump, yellow)
(13): Port PP1 hose (Front pump)
(14): Port PP2 hose (Rear pump)
(15): Port T hose (Oil cooler)

6.

Disconnect the following 4 control valve hoses:


(16): Port PPS1 hose (Front pump)
(17): Port PLS2 hose (Hose band: Red)
(18): Port PLS1 hose
(19): Port PX1 hose (Hose band: Blue)

7.

Remove relay bracket (20) and clamp (21).

8.

Disconnect drain hose (22). (To tank)

9.

Disconnect the following 6 left PPC hoses.


(23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm DUMP (Hose band: Yellow)

30-92 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

10. Disconnect 4 boom hoses (24).


11. Remove boom tube clamps (25) and (26).

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

DISASSEMBLY AND ASSEMBLY

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).

18. Lift off control valve assembly (40).


Control valve assembly: 250 kg (552 lb)

30-94 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

CONTROL VALVE

12
INSTALLATION

Carry out installation in the reverse order to removal.


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
See TESTING AND ADJUSTING, Bleeding air from each part.

PC400LC-7L

30-95 2

DISASSEMBLY AND ASSEMBLY


12
REPLACEMENT

CONTROL VALVE

PROCEDURE FOR PRESSURE COMPENSATION 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

(For 723-46-40100, 723-46-40601)


1

796-946-2110

Guide 20.9

(For 723-46-44100)
796-946-2210

Guide 20.6

(For 723-46-45100, 723-46-45500)


796-946-1320

Guide

(For 723-46-40100, 723-46-40601)


796-946-1420
2
L

Guide 21.6

(For 723-46-42800)
796-946-2120

Guide

(For 723-46-44100)
796-946-2220

Guide

(For 723-46-45100, 723-46-45500)


796-946-1330

Sleeve

(For 723-46-40100, 723-46-40601)


796-946-1430
3

Sleeve

(For 723-46-42800)
796-946-2130

Sleeve

(For 723-46-44100)
796-946-2230

Sleeve

(For 723-46-45100, 723-46-45500)

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

DISASSEMBLY AND ASSEMBLY

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.

Remove seal (5) and O-ring (6) from piston (2).


There many types of the pistons.
Clean the pressure compensation valve thoroughly. Then, using
the tool, install seals as shown in the figure.

3.

Fit O-ring (6) to piston (2).

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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)

Pressure compensation valve


When installing each pressure compensation valve, check the
mark made when it was removed.
Main relief valve assembly
After installing the main relief valve to the control valve, see TESTING AND ADJUSTING, Testing and adjusting oil pressures in work
equipment, swing, and travel circuits.

30-100 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

12

CENTER SWIVEL JOINT


REMOVAL
WARNING! Replace the remaining pressure in the
hydraulic circuit. For details, see TESTING
AND ADJUSTING, release of remaining
pressure in hydraulic circuit.
Mark all the piping with tags to prevent mistakes in the mount
position when installing.

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.

Disconnect nine hoses (7) through (15).


(7): Center swivel joint (E port) Left travel motor (P port)
(8): Center swivel joint (E port) Right travel motor (P port)
(9): Center swivel joint (D port) swing motor (T port)
(10): Center swivel joint (D port) Hydraulic tank
(11): Center swivel joint (E port) solenoid valve
(12): Center swivel joint (B port) Left travel control valve (B2
port)
(13): Center swivel joint (D port) Right travel control valve (B5
port)
(14): Center swivel joint (A port) Left travel control valve (A2
port)
(15): Center swivel joint (C port) Right travel control valve (A5
port)

3.

Pull out pin (16) on the side of center swivel joint and remove the jam
plate from the center swivel joint.

4.

Remove four mount bolts (17).

5.

Remove center swivel joint assembly (18). [*1]


Center swivel joint assembly: 40 kg (89 lb)

PC400LC-7L

30-101 2

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

12
INSTALLATION

Install in reverse order of removal.

[*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

DISASSEMBLY AND ASSEMBLY

CENTER SWIVEL JOINT

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.

Remove cover (1).

2.

Remove snap ring (2).

3.

Using tool M, pull out swivel rotor (4) and ring (3) from swivel shaft
(5).

4.

Remove seal (6) from swivel shaft (5).

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.

Assemble seal (6) in swivel shaft (5).

3.

Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install.
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.

Install ring (3) and secure with snap ring (2).

5.

Install O-ring and cover (1).


Mount bolt: 31.4 2.9 Nm {3.2 0.3 kgm}

PC400LC-7L

30-103 2

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT PPC VALVE

12

WORK EQUIPMENT PPC VALVE


Only precautions for assembling the work equipment PPC valve
assembly are explained below.

ASSEMBLY

Work equipment PPC valve assembly


Install springs (11) with the small-diameter (inside diameter)
end on the shim (12) side.
Springs (10) having different number of turns are used for the
following hydraulic ports. Take care when installing them.
Installed height: 31.9 mm (Common to all springs)
Installed load:
P1, P2: 35.3 N {3.6 kg} (7.9 lbf)
P3, P4: 21.6 N {2.2 kg} (4.85 lbf)
The position of each port is stamped on the underside of valve
body.
Piston (8): Grease (G2-LI)

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)

Female threads of body (A): Adhesive (LT-2)

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

DISASSEMBLY AND ASSEMBLY

TRAVEL PPC VALVE

12

TRAVEL PPC VALVE


DISASSEMBLY
Only precautions for assembling the travel PPC valve assembly are explained below.

ASSEMBLY

Travel PPC valve assembly


Insert shim (3) of the thickness and quantity checked when disassembled.
Standard shim thickness: 0.3 mm
Since spring (4) is not symmetric vertically, install it with the small-diameter (inside diameter) end on the shim side.
Periphery of piston (7) and inside of hole of body (1): Grease (G2-LI)

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

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

12

HYDRAULIC CYLINDER

Qty

790-502-1003

Cylinder repair stand

790-102-4300

Wrench assembly

790-102-4310

Pin

790-720-1000

Expander

796-720-1680

Ring (For boom and bucket)

07281-01589

Clamp (For boom and bucket)

796-720-1690

Ring (For arm)

07281-01919

Clamp (For arm)

790-201-1702

Push tool kit

790-201-1851

Push tool (For bucket)

790-201-1861

Push tool (For boom)

790-201-1871

Push tool (For arm)

790-101-5021

Grip

01010-50816

Bolt

2
3

N
5

Part Name

790-201-1500

Push tool kit

790-101-5021

Grip

01010-50816

Bolt

790-201-1660

Plate (For bucket)

790-201-1670

Plate (For boom)

790-201-1680

Plate (For arm)

Sketch

Part No.

New/Remodel

Symbol

Necessity

SPECIAL TOOLS

DISASSEMBLY
1.

Piston rod assembly


A. Remove the piping from the cylinder assembly.
B. Remove the mount bolts and disconnect cylinder head
assembly (1).
C. Pull out piston rod assembly (2).
Put a container under the cylinder to receive oil.

30-106 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

12
D. Disassemble the piston rod assembly according to the following
procedure.
i.

Set piston rod assembly (2) to tool N1.

ii. Remove piston assembly lock screw (3).


This work is common to the boom, arm, and bucket cylinders.
Screw size: M12 x Pitch 1.75

If screw (3) is so caulked that you cannot remove it, tighten it


temporarily and tap the threads on it, and then remove it.

iii. Using tool N2, remove piston assembly (4).

When not using tool N2, loosen the piston assembly


by using the drilled holes (10: 2 places) (in which the
pins of N2 are inserted in the figure at right).

PC400LC-7L

30-107 2

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CYLINDER

12
iv. Remove plunger (5).

Perform this work for only the boom and arm cylinder.
v.

Remove collar (6).

Perform this work for only the boom and arm cylinder.

vi. Remove head assembly (7).

vii. Remove cap (8), 11 balls (9), and plunger (10).

Perform this work for only the arm cylinder.


Since cap (8) is made of nylon, tighten a screw into it
and pull it with pliers.

2.

Disassembly of piston assembly


A. Remove rings (11).
B. Remove wear rings (12).
C. Remove piston ring (13).
D. Remove the O-ring and backup rings (14).

3.

Disassembly of cylinder head assembly


A. Remove the O-ring and backup ring (15).
B. Remove snap ring (16) and dust seal (17).
C. Remove rod packing (18).
D. Remove buffer ring (19).
E. Remove snap ring (21).
F.

Remove bushing (20).

30-108 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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.

Assembly of cylinder head assembly


A. Using tool N5, press fit bushing (20).
B. Install buffer ring (19).
C. Install rod packing (18).
D. Using tool N6, install dust seal (17) and secure it with snap ring
(16).
E. Install backup ring and O-ring (15).
F.

2.

Install snap ring (21).

Assembly of piston assembly


A. Using tool N3, expand piston ring (13).
Set piston ring (13) to tool N3 and turn the handle 8 - 10
times to expand the piston ring.
B. Set tool N4 and contract piston ring (13).

C. Install backup ring and O-ring (14).


D. Install wear ring (12).
E. Install ring (11).
Do not increase the closed gap of the ring too much.
Ring groove: Grease (G2-LI)

PC400LC-7L

30-109 2

DISASSEMBLY AND ASSEMBLY

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.

Perform this work for only the arm cylinder.

F.

Assemble piston assembly (4) according to the following


procedure.
When reusing the rod and piston assembly (4).
i.

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.

Perform this work for only the arm cylinder.


ii.

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

After tightening the piston, check that plunger (5) has


some play.
Perform this work for only the boom and arm cylinders.

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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.

Dimensions of screw hole (mm)


Tap drill diameter

Tap to be used

10.3

12 x 1.75
Tap drill hole
depth

Tapping
depth

Bucket/Boom

27

20

Arm

36

29

iv. Tighten screw (3).


Clean the parts thoroughly and remove metal chips, dirt, etc.
Threads of screw: Adhesive (LOCTITE No. 262)

Screw: 58.9 - 73.6 Nm {6 - 7.5 kgm} (43.4 - 54.2 lbf ft)


v.

Caulk the threaded part by 4 places with a punch.

G. Install piston rod assembly (2).


Set the abutment joint of the ring at a side and insert the
piston rod, aligning it with the cylinder tube.
After inserting the piston rod, check that the ring is not
broken or removed, and then insert to the end.

PC400LC-7L

30-111 2

DISASSEMBLY AND ASSEMBLY

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.

Install the piping.

30-112 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

Puller (490 kN {50t}, long)

790-101-1102

Pump (294 kN {30t})

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.

Disconnect grease hose (1).

2.

Sling boom cylinder assembly (2) temporarily and remove lock bolt and nut (3). [*1]

3.

Remove plate (4) and head pin (5). [*2]


Check the quantity and positions of the inserted shims.

4.

Start the engine and retract the piston rod.


Bind the rod with wires, etc. so that it will not be extracted and lower it onto a stand or put a wood block to the bottom
side so that the cylinder will not lower. When putting the wood block, remove the grease fitting on the bottom side.
Disconnect the boom cylinder on the opposite side similarly.
When slinging the boom cylinder, if the sling interferes with the work equipment lamp, remove the work equipment
lamp.

PC400LC-7L

30-113 2

DISASSEMBLY AND ASSEMBLY


5.

Disconnect intermediate connector A42 (6) for the work equipment


lamp.

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.

Sling work equipment assembly (12) temporarily.

8.

Remove cover (9), plate (10), and foot pin (11) to disconnect work
equipment assembly (12). [*3]

WORK EQUIPMENT

When removing with tool P


Remove plate (10). Sling and set tool P and remove foot pin (11)
to disconnect work equipment assembly (12).
Check the quantity and positions of the inserted shims.

9.

Move the machine in reverse to remove work equipment assembly


(12).
Work equipment assembly: 7,400 kg (16,315 lb)

30-114 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT

12
INSTALLATION

Carry out installation in the reverse order to removal.

[*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)

WARNING! When aligning the pin holes, never insert


your fingers in them.
Adjust the shim thickness so that clearance b between cylinder
rod (12) and plate (4) will be 1.5 mm or less.
Standard shim: 1.0, 2.0 mm
[*3]
Inside wall of bushing before assembling pin:
Anti-friction composition (LM-P)
Greasing after assembling pin: Grease (LM-G)

WARNING! When aligning the pin holes, never insert


your fingers in them.

Adjust the shim thickness so that clearance c between boom


(13) and bracket (14) will be 1 mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
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.

PC400LC-7L

30-115 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

12

OPERATORS CAB GLASS

1.

Right side window glass

2.

Left side rear window glass

3.

Door lower window glass

4.

Front window glass

5.

Front window assembly (Front window


glass + Front frame)

6.

Both-sided adhesive tape

7.

Center trim seal

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

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

Lifter (Suction cup)

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

Two-sided tape (DAM)

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).

If a seal cutter is not available, make holes on the adhesive and


both-sided adhesive tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes.
Grip the both ends of the wire with priors [3], etc. (or hold them
by winding them onto something) and move the wire to the right
and left to cut the adhesive and both-sided adhesive tape.
Since the wire may be broken by the frictional heat, apply
lubricant to it.
(The figure to the right shows the operator's cab of a wheel
loader.)
If the window glass is broken finely, it may be removed with knife
[4] and a screwdriver.
Widening the cut with a screwdriver, cut the adhesive and bothsided adhesive tape with knife [4].
(The figure to the right shows the operator's cab of a wheel
loader.)
2.

Remove the window glass.

PC400LC-7L

30-117 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

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.

Apply primer (10).


The using limit of primer (10) is 4 months after the date of
manufacture. Do not use primer (10) after this limit.
Use the primer within 2 hours after unpacking it.
Even if the primer is packed again just after it is unpacked, use it
within 24 hours after it is unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
A. Stir the primers for paint and glass sufficiently before using them.
If the primer has been stored in a refrigerator, leave it at the
room temperature for at least half a day before stirring it. (If
the primer is unpacked just after taken out of the refrigerator,
water will be condensed. Accordingly, leave the primer at the room temperature for a sufficient time.)
B. When reusing primer brush (11), wash it in white gasoline.
After washing the brush, check it again for dirt and foreign matter.
Prepare respective brushes for the paint primer glass primer.

30-118 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

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

Do not apply the primer more than 2 times. (If it is applied


more than 2 times, its performance will be lowered.)

Parts to be coated with primer: Apply the primer all over


dimension (a).
Dimension to apply primer (a): 25 mm

In addition to the above parts, apply the primer to right side


window glass (1) and door lower window glass (3).
Range to apply primer additionally for right side window
glass (1): (b)
Range to apply primer additionally for door lower window
glass (3): (c)
After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
Remark
Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.

PC400LC-7L

30-119 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

12
D. Evenly apply glass primer to the sticking surfaces of window
glass (9).
Glass primer: Yokohama G-200 or equivalent

Do not apply the primer more than 2 times. (If it is applied


more than 2 times, its performance will be lowered.)

Parts to be coated with primer:


Apply the primer to the sticking surfaces of window glass (9)
and all over dimension (d) which will be on both-sided
adhesive tape (6) and operator's cab (8).
Do not apply the primer to the boarder about 5 mm wide
between the black part and transparent part of the glass.
After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
Remark
Never apply wrong primer. If the glass primer is applied by
mistake, wipe it off with white gasoline.

4.

Stick both-sided adhesive tape (P/N 20Y-54-51531) (6) along the


inside edge of the glass sticking section.
Do not remove the release tape of the both-sided adhesive tape on
the glass sticking side before sticking the glass.
When sticking the both-sided adhesive tape, do not touch the
cleaned surface as long as possible.
Take that the both-sided adhesive tape will not float at each corner
of the window frame.
When sticking both-sided adhesive tape (6) around a frame, do
not lap its finishing end over the starting end but make clearance e
of about 5 mm between them.

A. Stick both-sided adhesive tape (6) for right side window glass (1).

30-120 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


12

OPERATORS CAB GLASS

Stick both-sided adhesive tape (6a) additionally for right side


window glass (1).
Positions to stick additional both-sided adhesive tape for right
side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm

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.

Stick both-sided adhesive tape (6b) additionally for door


lower window glass (3).
Positions to stick additional both-sided adhesive tape for door
lower window glass:
(j): 110 mm
(k): 90 mm
(m): 200 mm

PC400LC-7L

30-121 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

12
D. Stick both-sided adhesive tape (6) for front window glass (4) as
shown in the figure.

Stick both-sided adhesive tape (6c) of the lower side of the


front window glass along the outside edge of the lower line,
differently from other both-sided adhesive tapes (6). (If it is
stuck along the inside, it will be seen through the transparent
part of the glass.)

5.

Position the new window glass.


A. Check the clearance between the window glass and the operator's
cab on the right, left, upper, and lower sides, and then adjust it
evenly.
B. Stick tapes [6] between window glass (9) and operator's cab (8)
and draw positioning line n.
Stick tapes [6] to the right, left, and lower parts of the right
side window glass, left side rear window glass, and door
lower window glass for accurate positioning.
C. Cut the tape between window glass (9) and operator's cab (8) with
a knife, and then remove the window glass.
Do not remove the tapes left on the window glass and
operator's cab before installing the window glass.

30-122 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY


12

6.

OPERATORS CAB GLASS

When positioning front window glass (4), set its horizontal


position to the frame width and set its vertical position so that
height difference (p) between it and the frame top will be 3
mm.

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

C. Set adhesive cartridge (12) to caulking gun [7].


An electric caulking gun is more efficient.

PC400LC-7L

30-123 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

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.

Apply adhesive (15) to dimensions (s) and (t) of both-sided


adhesive tape (6) of operator's cab (8).
Dimension (s): 10 mm
Dimension (t): 15 mm
Apply adhesive (15) higher than both-sided adhesive tape (6).
Apply the adhesive evenly.

Apply adhesive (15) additionally for additional both-sided


adhesive tape (6a) of the right side window glass and
additional both-sided adhesive tape (6b) of door lower
window glass.

30-124 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

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.

You can perform this work efficiently by pulling window


glass (9) from inside of the operator's cab with suction cup
Y1.

After installing front window glass (4), fill the clearances


between it and center trim seal (16) with caulking material in
range (s) to dimensions (t) and (u). After applying the primer
to glass (4) of section A A, apply adhesive as caulking
material.
Caulking dimension (t): 2 mm
Caulking dimension (u): 5 mm
When caulking, mask the glass side and form the adhesive
with a rubber spatula as shown in the figure.
Wipe off projected adhesive.
Glass primer: Yokohama G-200

Adhesive: Sikaflex 256HV

PC400LC-7L

30-125 2

DISASSEMBLY AND ASSEMBLY

OPERATORS CAB GLASS

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.

10. Protect the stuck window glass.


A. Keep the stopper rubbers, styrene foam blocks, and rubber bands
installed for 10 hours (at temperature of 20C (68F) and
humidity of 60%).
B. After removing the stopper rubbers, styrene foam blocks, and rubber bands, wait at least 14 hours, at least 24 hours in
total, before operating the machine actually.

30-126 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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.

Release the rear locks.

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

DISASSEMBLY AND ASSEMBLY

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.

10. Lower front window assembly (13) completely.


Do not let the front window assembly touch the monitor.

30-128 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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.

If there is any problem in opening or closing of the front window,


loosen the mount bolts of roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and then tighten the mount
bolts again.
Mount bolt: 98 Nm {1.0 kgm} (72.2 lbf ft)

30-130 2

PC400LC-7L

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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

DISASSEMBLY AND ASSEMBLY

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.

Adjust the opening lock of the front window assembly.


A. After adjusting the closing lock of the front window in steps 6
and 7, raise the front window assembly to the ceiling.
B. Check the working condition of both front window assembly
opening locks in the rear of the operator's cab.
C. If the locks do not work normally, move both striker plates (22) in
the rear of the operator's cab forward and in reverse and fix them
at places where the locks work normally.

PC400LC-7L

30-133 2

DISASSEMBLY AND ASSEMBLY

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.

11. Check the latching effort of the front window assembly.


A. After finishing steps 6 - 10, check that latching efforts of both
locks (20) and (21) are even.
Check the latching efforts on both closing side (in the front
of the operator's cab) and opening side (in the rear of the
operator's cab).
[*3]
Left lower pin:
27 - 34 Nm {2.75 - 3.47 kgm} (20 - 25 lbf ft)
Mount bolt: Adhesive (LT-2)

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

HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1

PC400LC-7L

90-3

OTHERS

HYDRAULIC

MEMORANDUM

90-4

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2

90-5

OTHERS

HYDRAULIC

MEMORANDUM

90-6

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3

90-7

OTHERS

HYDRAULIC

MEMORANDUM

90-8

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4

90-9

OTHERS

HYDRAULIC

MEMORANDUM

90-10

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5

90-11

OTHERS

HYDRAULIC

MEMORANDUM

90-12

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6

90-13

OTHERS

HYDRAULIC

MEMORANDUM

90-14

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7

90-15

OTHERS

HYDRAULIC

MEMORANDUM

90-16

PC400LC-7L

OTHERS
12
HYDRAULIC

PC400LC-7L

HYDRAULIC

DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8

90-17

OTHERS

HYDRAULIC

MEMORANDUM

90-18

PC400LC-7L

OTHERS

ELECTRICAL

12

ELECTRICAL

ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9

PC400LC-7L

90-19

OTHERS

ELECTRICAL

MEMORANDUM

90-20

PC400LC-7L

OTHERS

ELECTRICAL

ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10

PC400LC-7L

90-21

OTHERS

ELECTRICAL

MEMORANDUM

90-22

PC400LC-7L

OTHERS
12
ELECTRICAL

PC400LC-7L

ELECTRICAL

DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11

90-23

OTHERS

ELECTRICAL

MEMORANDUM

90-24

PC400LC-7L

OTHERS

ELECTRICAL

ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12

PC400LC-7L

90-25

OTHERS

ELECTRICAL

MEMORANDUM

90-26

PC400LC-7L

OTHERS
12
ELECTRICAL

PC400LC-7L

ELECTRICAL

DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13

90-27

OTHERS

ELECTRICAL

MEMORANDUM

90-28

PC400LC-7L

OTHERS
12
ELECTRICAL

PC400LC-7L

ELECTRICAL

DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14

90-29

OTHERS

ELECTRICAL

MEMORANDUM

90-30

PC400LC-7L

OTHERS
12
ELECTRICAL

PC400LC-7L

ELECTRICAL

DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15

90-31

OTHERS

ELECTRICAL

MEMORANDUM

90-32

PC400LC-7L

OTHERS
12
ELECTRICAL

PC400LC-7L

ELECTRICAL

DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16

90-33

OTHERS

ELECTRICAL

MEMORANDUM

90-34

PC400LC-7L

OTHERS
12
M

ELECTRICAL

CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17

PC400LC-7L

90-35

OTHERS

ELECTRICAL

MEMORANDUM

90-36

PC400LC-7L

OTHERS
12
M

ELECTRICAL

CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18

PC400LC-7L

90-37

OTHERS

ELECTRICAL

MEMORANDUM

90-38

PC400LC-7L

OTHERS
12
E CIRCUIT

PC400LC-7L

ELECTRICAL

(ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19

90-39

OTHERS

ELECTRICAL

MEMORANDUM

90-40

PC400LC-7L

OTHERS
12
E CIRCUIT

PC400LC-7L

ELECTRICAL

(ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20

90-41

OTHERS

ELECTRICAL

MEMORANDUM

90-42

PC400LC-7L

OTHERS
12
P CIRCUIT

PC400LC-7L

ELECTRICAL

(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21

90-43

OTHERS

ELECTRICAL

MEMORANDUM

90-44

PC400LC-7L

OTHERS
12
P CIRCUIT

PC400LC-7L

ELECTRICAL

(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22

90-45

OTHERS

ELECTRICAL

MEMORANDUM

90-46

PC400LC-7L

OTHERS
12
P CIRCUIT

PC400LC-7L

ELECTRICAL

(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23

90-47

OTHERS

ELECTRICAL

MEMORANDUM

90-48

PC400LC-7L

OTHERS
12
P CIRCUIT

PC400LC-7L

ELECTRICAL

(PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24

90-49

OTHERS

ELECTRICAL

MEMORANDUM

90-50

PC400LC-7L

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