SEN00628-00 40 Troubleshooting

S-1 Starting performance is poor 1

General causes why starting performance is poor Cause

Cracked EGR cooler (Coolant in exhaust piping)

• Defective electrical system
• Insufficient supply of fuel

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat

Defective alternator (generator section)

• Insufficient intake of air

Defective alternator (regulator section)

• Improper selection of fuel

Stuck, seized supply pump plunger

Defective intake air heater system

Defective or deteriorated battery

• Coolant in exhaust piping

Clogged feed pump gauze filter

Clogged air cleaner element

Clogged fuel filter, element

Worn piston ring, cylinder
a The common rail fuel injection system (CRI) recognizes the fuel injec-
tion timing electrically. Accordingly, even if the starting operation is car-
ried out, the engine may not start until the crankshaft revolves 2 turns

Defective injector
at maximum. This phenomenon does not indicate a trouble, however.

Confirm recent repair history

Degree of use of
Operated for long period E E E E E
machine
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Questions

Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally w
(if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
While engine is cranked not flow out w w
with starting motor
Check items

If spill hose from injector is disconnected, little fuel spills w

When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows out
q
(*1)
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting

Inspect fuel filter, strainer directly q

Inspect gauze filter of feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for failure
q
code.
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace

Replace

Replace
Replace
Replace
Replace
Replace
Replace
Correct

Correct
Clean

Clean

Clean
Clean

Remedy

8 PC400, 450-7E0
40 Troubleshooting SEN00628-00

*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.

*2: Failure codes [CA559] and [CA2249]

PC400, 450-7E0 9
SEN00628-00 40 Troubleshooting

S-2 Engine does not start 1

a) Engine does not turn Cause

Cracked EGR cooler (Coolant in exhaust piping)

General causes why engine does not turn

Defective starting motor (safety relay section)

• Internal parts of engine seized:

Defective connection of battery terminal

Defective starting motor (motor section)

See “S-4 Engine stops during operations”
• Coolant entered in cylinder, producing water hammer

Defective or deteriorated battery

• Defective electrical system

Defective starting circuit wiring

• Defective hydraulic pump

Broken flywheel ring gear

Defective hydraulic pump

Defective starting switch
Defective battery relay
Confirm recent repair history
Degree of use of
Questions

Operated for long period EEE

machine
Condition of horn Horn does not sound Q Q w
when starting switch
is turned ON Horn volume is low w

Battery electrolyte is low w

Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items

Speed of rotation is low Q w

When starting switch
is turned to START, Makes grating noise w w
starting pinion moves Soon disengages again w
out, but
Makes rattling noise and does not turn w Q Q w

When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
q
out (*1)
Carry out troubleshooting in H-mode
Carry out troubleshooting in E-mode

Inspect flywheel ring gear directly q

When specific gravity of electrolyte and voltage of battery are measured, they are
q
Troubleshooting

low
There is not voltage (20 – 30 V) between battery relay termi-
q
nal M and terminal E
Turn starting switch When terminal B and terminal C of starting switch are con-
q
OFF, connect cord, nected, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are con-
shooting at ON q
nected, engine starts
Even if terminal B and terminal C at safety relay outlet are
q
connected, engine does not start
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Correct

Remedy
—
—

10 PC400, 450-7E0
40 Troubleshooting SEN00628-00

*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.

PC400, 450-7E0 11
SEN00628-00 40 Troubleshooting

b) Engine turns but no exhaust smoke comes out Cause

Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes out

• Fuel is not being supplied

• Supply of fuel is extremely small

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
• Improper selection of fuel (particularly in winter)

Wrong connection of supply pump PCV

Seized, abnormally worn feed pump

Stuck, seized supply pump plunger

Clogged feed pump gauze filter

Broken supply pump shaft key

Defective supply pump PCV

Malfunction of flow damper

Clogged fuel filter element
Insufficient fuel in tank

Defective fuel injector

Use of improper fuel
Confirm recent repair history
Degree of use
EEE
Questions

Operated for long period

of machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
and Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

When priming pump is operated, it makes no reaction or it is heavy w Q Q

If air bleeding plug of fuel filter is removed, fuel does
While engine is not flow out Q Q w Q
cranked with
starting motor If spill hose from injector is disconnected, little fuel
Q w w w w Q
spills

When air is bled from fuel system, air comes out q

Inspect fuel filter directly q
Inspect gauze filter of feed pump directly q
Troubleshooting

Inspect feed pump directly q

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)”
q q q q
See *1 for failure code.
Carry out troubleshooting for “PCV1 Error (*2) or PCV2 Error (*3).”
q
See *2 or *3 for failure code.
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Replace
Correct
Correct

Correct
Clean

Remedy
Add

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA271] and [CA272]
*3: Failure codes [CA273] and [CA274]

12 PC400, 450-7E0
40 Troubleshooting SEN00628-00

c) Exhaust smoke comes but engine does not start Cause

Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)

Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does not start

Excessive wear of piston ring, cylinder liner

Leaking or clogged fuel system, entry of air

• Lack of rotating force due to defective electrical system

Clogged air breather hole of fuel tank cap

• Insufficient supply of fuel
• Insufficient intake of air

Stuck, seized supply pump plunger

Defective intake air heater system

• Improper selection of fuel

Clogged injector, defective spray

Clogged feed pump gauze filter

Defective, deteriorated battery

Clogged air cleaner element

Clogged fuel filter, strainer

Use of improper fuel
Confirm recent repair history
Degree of use of
Operated for long period E EE E
machine
Suddenly failed to start w w Q
Questions

Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte-
w w w
nance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items

While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
Q w w
cranked with starting out
motor If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Inspect air cleaner directly q
Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
When air is bled from fuel system, air comes out q
Troubleshooting

Inspect fuel filter, strainer directly q

Inspect gauze filter of feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for failure code. q
When injector is tested alone, condition of spray is poor q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Coolant temperature gauge does not indicate normally (if the gauge is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Correct
Clean

Clean

Clean
Clean

Clean

Remedy

*1: Failure codes [CA559] and [CA2249]

PC400, 450-7E0 13
SEN00628-00 40 Troubleshooting

S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Cause

Malfunction of flow damper (Leakage from injector is large)

• Insufficient intake of air
• Insufficient supply of fuel
• Defective condition of fuel injection

Seized turbocharger, interference of turbocharger

• Improper selection of fuel
• Controller is controlling in derate mode

Excessive wear of piston ring, cylinder liner

Leaking or clogged fuel piping, entry of air

• (limiting injection rate (output) because of an error in electrical system)

Clogged air breather hole of fuel tank cap

Defective contact of valve and valve seat
• EGR valve is stuck and is open
(Excessive EGR gas, insufficient intake of air)

Stuck, seized supply pump plunger

Clogged injector, defective spray

Clogged feed pump gauze filter
Clogged air cleaner element

Clogged fuel filter, strainer

Improper valve clearance
Stuck EGR valve
Confirm recent repair history
Degree of use of
Operated for long period EEE E EE
machine
Questions

Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and Mainte-
w w w
nance Manual
Engine oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Rust and water are found when fuel tank is drained w w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
Q w
some cylinders is low
Color of exhaust Blue under light load w
Check items

gas Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q
Carry out troubleshooting for “EGR Valve Servo Error. (*1)” See *1 for failure code. q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Inspect gauze filter of feed pump directly q
Carry out troubleshooting for “Rail Press (Very) Low Error. (*2)” See *2 for failure code. q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Replace
Replace

Replace
Replace

Replace
Replace
Correct

Correct
Adjust
Clean

Clean

Clean
Clean

Remedy

*1: Failure codes [CA1228] and [CA1625]

*2: Failure codes [CA559] and [CA2249]

14 PC400, 450-7E0
40 Troubleshooting SEN00628-00

S-4 Engine stops during operations 1

General causes why engine stops during operations Cause

Broken dynamic valve system (valve, rocker arm, etc.)

• Seized parts inside engine
• Insufficient supply of fuel
• There is overheating
• Defective hydraulic pump

Clogged air breather hole of fuel tank cap

Broken, seized piston, connecting rod

Stuck, seized supply pump plunger

Broken, seized crankshaft bearing

Clogged feed pump gauze filter

Broken supply pump shaft key

Leaking, clogged fuel piping
Clogged fuel filter, strainer

Broken, seized feed pump

Defective hydraulic pump

Broken, seized gear train
Insufficient fuel in tank
Confirm recent repair history
Degree of use of
Operated for long period EE
machine
Abnormal noise was heard and engine stopped suddenly w w w w Q w Q w
Questions

Condition when engine Engine overheated and stopped w Q

stopped Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
w w
nance Manual
Fuel level monitor indicates low level (if monitor is installed) w
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Rust and water are found when fuel tank is drained w w
Check items

Metal particles are found when oil pan is drained w w Q Q

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect dynamic valve system directly q

Carry out troubleshooting in H-mode

Inspect piston, connecting rod directly q

Inspect crank shaft bearing directly q

Troubleshooting

Inspect gear train directly q

Inspect fuel filter, strainer directly q

Inspect gauze filter of feed pump directly q

Inspect feed pump directly q

Carry out troubleshooting for “Rail Press (Very) Low Error. (*1)” See *1 for code. q q
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Correct
Clean

Clean
Clean

Remedy
—
Add

*1: Code [559/CA559] and code [2249/CA2249] in E-mode

PC400, 450-7E0 15